Film blowing of thermoplastic starch

Thermoplastic starch materials are often based on a combination of starch, glycerol and water. In the present study, two potato starch grades were employed; a native (natural) grade and an oxidised and hydroxypropylated grade of the native material, in order to produce the thermoplastic material. The primary aim of the study was to identify possible routes for film blowing thermoplastic starch on a laboratory scale by a suitable choice of processing conditions, amount of glycerol and moisture content. With an appropriate combination of these parameters, the thermoplastic material based on the modified starch could be film blown in a satisfactory manner. Film blowing of material based on the natural starch was significantly more difficult. The difficulties encountered were mainly related to a sticky surface of the film, insufficient tenacity and foaming. The processing window for thermoplastic starch (related to film blowing) is briefly outlined and discussed.     

The effects of different starch sources and plasticizers on film blowing of thermoplastic starch: Correlation among process,elongational properties and macromolecular structure

The material compositions and the technological procedures to prepare biodegradable films with the film blowing technology based on thermoplastic starch were studied in this work. The activities were focused on the analysis of the effects of starch source (maize, potato and wheat), supplier (Roquette, Cerestar and Cameo) and the type of plasticizers (glycerol, urea and formamide) and their content on the physical–chemical and mechanical properties. Moreover, in order to develop a film blowing technology, material composition as well as processing condition were optimized. Among 10 varieties of thermoplastic starch prepared, the combination of urea and formamide as plasticizer restrained retrogradation and improved mechanical properties. Extensional rheological properties of the thermoplastic starch films were also investigated: the results showed that the occurrence of strain-hardening behaviour in some of the investigated compositions lead to a positive effect on the film blowing process. In this study we found that the combination of high-amylose (>51%) starch and urea/formamide mixtures as plasticizer produced an homogenous film of a 50 μm thickness and a robust film blowing process due to the good elongational viscosity, high deformability of the melt and strain-hardening behaviour.     

Microstructural characterization of yam starch films

Yam starch films were produced by thermal gelatinization of starch suspensions using different starch and glycerol concentrations and were compared to control samples without glycerol. Films were characterized by polarized light microscopy, scanning electron microscopy (SEM), differential scanning calorimetry (DSC), thermomechanical analysis (TMA), X-ray diffraction, water vapor permeability (WVP) and water sorption isotherms. The polarized light microscopy and DSC data showed that starch gelatinization for film formation was complete. Plasticized films have a homogeneous structure as observed by SEM. At water activities >0.43, glycerol increased the equilibrium moisture content of the films due to its hydrophilic character. X-ray pattern of the yam films could be assigned to a B-type starch; during storage this pattern remained almost the same, however a slight recrystallization process could be observed. Amylopectin retrogradation was not observed by DSC with storage time of the films. Glass transition temperatures of films with glycerol were lower than those of control films as measured by DSC and TMA. WVP of yam starch films increased with the presence of glycerol.     

Effect of orientation on the physical properties of potato amylose and high-amylose corn starch films

The effect of orientation on the properties of amylose and starch films was studied in order to determine if film strength, flexibility, and water resistance could be improved. Potato amylose and high (70%) amylose corn starch were peracetylated, cast into films, stretched in hot glycerol 1-6 times the original length, and deacetylated. Molecular orientation of potato amylose films was much higher than for high-amylose corn starch films as determined by optical birefringence. For potato amylose films, orientation resulted in large increases in tensile strength and elongation but little change in modulus. For high-amylose corn starch films, tensile strength and modulus did not change with draw ratio but elongation to break increased from about 8% to 27% as draw ratio increased from 1 to 5. Scanning electron micrographs revealed many small crazes in the drawn starch films, suggesting that the improved film toughness was due to energy dissipation during deformation of the crazes. Annealing of drawn films at 100% humidity resulted in partial crystallization and improved wet strength.     

Glycerol-plasticized films prepared from starch—poly(vinyl alcohol) mixtures: effect of poly(ethylene-co-acrylic acid)

Equations were obtained from response surface models to show how the ultimate tensile strength (UTS) and percent elongation at break (%E) of solution-cast films vary with relative amounts of starch, poly(vinyl alcohol) (PVA), poly(ethylene-co-acrylic acid) (EAA) and glycerol in the formulation. Equations found from the response surface methodology were used to optimize the relative amounts of the four components with respect to the physical properties of cast films. The model showed that only glycerol content was important to predict the UTS of the films. The model for %E was more complicated, since there was a three-way interaction between EAA, PVA and glycerol. This model also contained two other terms: a two-way interaction evolving glycerol and EAA. and a (PVA)³ term. In general, %E increased as EAA, PVA and glycerol were increased together. However, increased amounts of EAA could decrease %E if EAA was the only component increased. It is believed that EAA forms complexes with both starch and PVA, thereby increasing compatibility of the two polyhydroxy polymers. As %E increases, UTS of the films decreases. All the films produced in this paper were made with starch contents above 50% to insure an optimum film formulation with at least 50% starch. A mixture of 55·6% starch, 2·8% EAA, 28·3% PVA and 13·3% glycerol is believed to be close to the optimum formulation to obtain films having at least 100%E and UTS of 25 MPA, while still maintaining starch concentrations above 50%.     

Influence of thickness on the mechanical properties for starch films

The aim of the present study was to investigate some mechanical properties of starch films. Starch is a natural common polymer in nature and the use of natural materials is increasing in the industries. In this study, the mechanical properties of starch plasticized with 30 parts by weight, of glycerol, are investigated. For the mechanical testing films of different thickness were used, the thickness varied between 0.5 and 2.5 mm. T_g was measured with a differential scanning calorimeter and with a dynamical mechanical analysis. The starch films were tested in tension and characterised in terms of stiffness, strength and failure strain. Fracture toughness was measured by single edge notch tests. Both stiffness and strength showed a strong dependence on film thickness, stronger then expected from linear fracture mechanics. This can be due to the different molecule orientation in the films, and due to the crystallinity of the films.     

Compression molding and tensile properties of thermoplastic potato starch materials

The mechanical and melt flow properties of two thermoplastic potato starch materials with different amylose contents were evaluated. The materials were prepared by mixing starch, glycerol, and water, mainly in the weight proportions of 10:3:4.5. Compression molding was used to produce sheets/films with a thickness in the range of 0.3-1 mm. After conditioning at 53% relative humidity (RH) and 23 C, the glycerol-plasticized sheets with a higher amylose content (HAP) were stronger and stiffer than the normal thermoplastic starch (NPS) with an amylose content typical for common potato starch. The tensile modulus at 53% RH was about 160 MPa for the high-amylose material and about 120 MPa for the plasticized NPS. The strain at break was about 50% for both materials. The stress at break was substantially higher for the HAP materials than for the NPS materials, 9.8 and 4.7 MPa, respectively. Capillary viscometry at 140 C showed that the high-amylose material had a higher melt viscosity and was more shear-thinning than the NPS. Dynamic mechanical measurements indicated a broad transition temperature range for both types of starch material. The main transition peaks for glycerol-plasticized starch were located at about room temperature with the transition for the HAP material being at a somewhat higher temperature than that of the NPS material with a lower amylose content. It was also noted that the processing conditions used during the compression molding markedly affected the mechanical properties of the starch material.     

Maleated thermoplastic starch by reactive extrusion

Novel maleated thermoplastic starch (MTPS) with both improved processing and reactivity useful in the melt-blending with biodegradable polyester was prepared through in situ reactive modification of thermoplastic starch (TPS) with maleic anhydride (MA) as esterification agent. Glycerol was used as plasticizer. Physico-chemical parameters of MTPS were determined at different MA contents, while keeping both the content in glycerol (20 wt% by starch), and the processing temperature constant (150 °C). Soxhlet extraction attested for the complete incorporation of glycerol into the starch backbone during the maleation process at low content in MA. In addition, two-dimensional liquid-phase NMR measurements attested for the preferential esterification of starch backbone at C6, together with the occurrence of some hydrolysis and glucosidation reactions. Such reactions promoted by MA moieties reduced the intrinsic viscosity of the MTPS, expecting an improvement in its processability. WAXS diffraction analyses confirmed the complete disruption of the granular structure of native starch in MTPS during the reactive extrusion processing.     

Extrusion processing of high amylose potato starch materials

Thermoplastic starch was prepared by mixing native high amylose potato starch and normal potato starch in a Buss co-kneading extruder at starch to glycerol ratios of 100:45 and 100:30. The materials were also conditioned to different moisture contents at different relative humidities at 23 °C. After the mixing, the compounds were extruded into sheets with a Brabender laboratory extruder. The thermoplastic high amylose materials exhibited a higher melt viscosity than the normal potato starch materials when conditioned at 53% relative humidity. Increasing the moisture content in HAP from 27% to 30% (by weight) lowered the melt viscosity to the same level as that of normal potato starch with a moisture content of 28%. In general, the high amylose materials were more difficult to extrude than the thermoplastic material based on normal starch. The main extrusion problems encountered with the high amylose starch were unstable flow, insufficient melt tenacity and clogging of the die. By increasing the moisture content, increasing the compression ratio of the screw and increasing the rotation rate of the screw, the problems were reduced or eliminated. However, only with a starch to glycerol ratio of 100:45 was an acceptable extrusion result obtained. Extruded sheets of such high amylose materials had a stress at break of about 5 MPa at room temperature and 53% relative humidity, whereas the corresponding value for normal potato (thermoplastic) starch was 3 MPa. The elongation at break was also higher in the case of the high amylose material. The results are discussed in terms of residual crystallinity of the starch materials.     

Biodegradability and mechanical properties of starch films from Andean crops

Different Andean crops were used to obtain starches not previously reported in literature as raw material for the production of biodegradable polymers. The twelve starches obtained were used to prepare biodegradable films by casting. Water and glycerol were used as plasticizers. The mechanical properties of the starch based films were assessed by means of tensile tests. Compost tests and FTIR tests were carried out to assess biodegradability of films. The results show that the mechanical properties (UTS, Young's modulus and elongation at break) of starch based films strongly depend on the starch source used for their production. We found that all the starch films prepared biodegrade following a three stage process and that the weight loss rate of all the starch based films tested was higher than the weight loss rate of the cellulose film used as control.     

Characterization of citric acid/glycerol co-plasticized thermoplastic starch prepared by melt blending

A novel citric acid (CA)–glycerol co-plasticized thermoplastic starch (CGTPS) was prepared by melt blending. The CA content varies from 10% to 40 wt%. Result from Fourier Transform Infrared spectroscopy (FTIR) show that partial esterification occurred during blending. The degrees of substitution and esterification increased as the CA content increased. Results from intrinsic viscosity measurement, laser light scattering (LLS), and FTIR demonstrate the molecular weight of starch decreased as the CA percentage increased. The weight average molecular weight (M_w) of CGTPS with 20 wt% CA was only one-tenth of that without CA under the same processing conditions. Crystal type and crystallinity changes as a function of CA were recorded by X-ray diffraction (XRD). Thermal stability and the glass transition temperature (T_g) were detected by thermogravimetric (TG) and differential scanning calorimeter (DSC). Compared to the traditional GTPS, the novel CGTPS exhibits the special characters of partial esterification, low molecular weight and stronger interaction between starch and plasticizers. These new properties can be expected to prevent retrogradation, promote compatibility with polyesters, improve the processing ability, and adjust the degradation properties.     

Cassava bagasse cellulose nanofibrils reinforced thermoplastic cassava starch

Cellulose cassava bagasse nanofibrils (CBN) were directly extracted from a by-product of the cassava starch (CS) industry, viz. the cassava bagasse (CB). The morphological structure of the ensuing nanoparticles was investigated by scanning electron microscopy (SEM), transmission electron microscopy (TEM), atomic force microscopy (AFM), presence of other components such as sugars by high performance liquid chromatography (HPLC), thermogravimetric analysis (TGA), and X-ray diffraction (XRD) experiments. The resulting nanofibrils display a relatively low crystallinity and were found to be around 2–11 nm thick and 360–1700 nm long. These nanofibrils were used as reinforcing nanoparticles in a thermoplastic cassava starch matrix plasticized using either glycerol or a mixture of glycerol/sorbitol (1:1) as plasticizer. Nanocomposite films were prepared by a melting process. The reinforcing effect of the filler evaluated by dynamical mechanical tests (DMA) and tensile tests was found to depend on the nature of the plasticizer employed. Thus, for the glycerol-plasticized matrix-based composites, it was limited especially due to additional plasticization by sugars originating from starch hydrolysis during the acid extraction. This effect was evidenced by the reduction of glass vitreous temperature of starch after the incorporation of nanofibrils in TPSG and by the increase of elongation at break in tensile test. On the other hand, for glycerol/sorbitol plasticized nanocomposites the transcrystallization of amylopectin in nanofibrils surface hindered good performances of CBN as reinforcing agent for thermoplastic cassava starch. The incorporation of cassava bagasse cellulose nanofibrils in the thermoplastic starch matrices has resulted in a decrease of its hydrophilic character especially for glycerol plasticized sample.     

Super-absorbent polymers from starch-polyacrylonitrile graft copolymers by acid hydrolysis before saponification

Graft copolymers (SPAN) of polyacrylonitrile (PAN) onto starch were prepared from gelatinized starch varieties with ammonium ceric nitrate as an initiator. The molecular weight of the PAN branches increased for the varieties of starches in the order high amylose maize starch < maize starch < waxy maize starch. SPAN samples were saponified with aqueous NaOH, and the aqueous solution of the resulting polymer (HSPAN) was cast into film in a forced-air oven at 35°C. The water absorbency of the HSPAN film formed from waxy maize starch was the highest (1200 g H₂O (g dry sample)⁻¹) and that from high amylose maize starch was the lowest (530 g g⁻¹). SPAN samples from maize starch were partially hydrolyzed with dilute hydrochloric acid. The resulting polyacrylonitriles with low molecular weight starch end groups (LSPAN) were also saponified. The resulting saponified product (HLSPAN) was cast into film. The absorbencies of HLSPAN films were found to be far larger (up to 6000 g g⁻¹) than those of the corresponding HSPAN films. The absorbency increased with increasing molecular weight of PAN in the initial SPAN up to a molecular weight of 1−1·5 × 10⁶. The absorbency decreased significantly when HSPAN and HLSPAN films were subjected to heat treatment at 135°C or above. The crosslinks present in HSPAN and HLSPAN films prepared at 35°C and those formed during heat treatment were considered to have different structures: the former formed between carbohydrate alkoxide ions and nitrile groups at the early stages of saponification and the latter formed between carbohydrate and copoly(acrylate-acrylamide) chains and/or between copoly(acrylate-acrylamide) chains.     

Film forming capacity of chemically modified corn starches

Native starch can be chemically modified to improve its functionality and to expand its uses. Modified starches were characterized and the rheological behavior of filmogenic suspensions was analyzed. The film forming capacity of different chemical modified corn starches was evaluated. Acetylated starch was selected by the characteristics of the resulted films; its optimum concentration was 5% w/w since their films exhibited the lowest water vapor permeability (WVP, 1.26 × 10⁻¹⁰ g/m s Pa). The effect of glycerol as plasticizer on film properties depend on its concentration, being 1.5% w/w those that allows to obtain the lowest WVP value (1.64 × 10⁻¹¹ g/m s Pa), low film solubility in water and a more compact structure than those of unplasticized films. Mechanical behavior of plasticized acetylated starch films depends on glycerol concentration, being rigid and brittle the unplasticized ones, ductile those containing 1.5% w/w of glycerol and very flexible those with a higher plasticizer content.     

Extrusion of pectin/starch blends plasticized with glycerol

The microstructural and thermal dynamic mechanical properties of extruded pectin/starch/glycerol (PSG) edible and biodegradable films were measured by scanning electron microscopy (SEM) and thermal dynamic mechanical analysis (TDMA). SEM revealed that the temperature profile (TP) in the extruder and the amount of water present during extrusion could be used to control the degree to which the starch was gelatinized. TDMA revealed that moisture and TP during extrusion and by inference the amount of starch gelatinization had little effect on the mechanical properties of PSG films. Furthermore, TDMA revealed that PSG films underwent a glass transition commencing at about −50°C and two other thermal transitions above room temperature. Finally, it was concluded that the properties of extruded PSG films were comparable to those cast from solution.     

Enhanced film forming and film properties of amylopectin using micro-fibrillated cellulose

This work describes a novel approach to produce amylopectin films with enhanced properties by the addition of microfibrillated cellulose (MFC). Aqueous dispersions of gelatinized amylopectin, glycerol (0–38 wt%) and MFC (0–10 wt%) were cast at ambient temperature and 50% relative humidity and, after 10 days of storage, the tensile properties were investigated. The structure of the composite films was revealed by optical, atomic force and transmission electron microscopy. The moisture content was determined by thermogravimetry and the temperature-dependent film rigidity was measured by thermal mechanical analysis. Synchrotron simultaneous small- and wide-angle X-ray measurements revealed that the solutions had to be heated to above 85 °C in order to achieve complete gelatinization. Optical microscopy and atomic force microscopy revealed uniformly distributed MFC aggregates in the films, with a length of 10–90 μm and a width spanning from a few hundred nanometers to several microns. Transmission electron microscopy showed that, in addition to aggregates, single MFC microfibrils were also embedded in the amylopectin matrix. It was impossible to cast amylopectin films of sufficient quality with less than 38 wt% glycerol. However, when MFC was added it was possible to produce high quality films even without glycerol. The film without glycerol was stiff and strong but not brittle. It was suggested that this remarkable effect was due to its comparatively high moisture content. Consequently MFC acted both as a “conventional” reinforcement because of its fibrous structure and also indirectly as a plasticiser because its presence led to an increase in film moisture content.     

Effect of glycerol on behaviour of amylose and amylopectin films

The effect of water and glycerol on sorption and calorimetric T_gs of amylose and amylopectin films were examined. The mechanical properties of the films were also analysed under varying glycerol content at constant RH and temperature. Based on changes observed in sorption and tensile failure behaviour glycerol was strongly interacted with both starch polymers. Even though water was observed to be more efficient plasticiser than glycerol, glycerol also affected the T_g. But in spite of the observed decrease in T_g under low glycerol contents brittleness of the films increased based on changes in elongation. The increase in brittleness of both polymers was also in agreement with their actual behaviour. At around 20% glycerol great change in the rheological properties occurred. Above 20% glycerol amylose film showed much larger elongation than the low glycerol content films and was still strong but the amylopectin produced a very week and non-flexible film.     

In vitro digestibility of edible films from various starch sources

Banana, maize, potato and sagu starches were boiled in the presence or absence of plasticizer (glycerol), producing edible films. In vitro digestibility features, amylose content and amylopectin gel filtration behavior of films and parent starches were evaluated. Available starch contents were lower in glycerol-containing films, due to dilution by the plasticizer. Total resistant starch increased in the maize starch-based film but decreased markedly in those prepared from the other starches. Amylose content of banana starch (40%) was about double those of the other starches. Nonetheless, all starch films exhibited similar retrograded resistant starch content. Although film production led to increased -amylolysis rates, these were further augmented by additional film heating, thereby indicating that film-manufacture did not promote complete starch gelatinization. Gel filtration chromatography suggested amylopectin depolymerization after film-making, which may also increase digestion kinetics. The presence of glycerol in the films slowed down starch digestion, a feature of potential dietetic use.     

Aging properties of films of plasticized vital wheat gluten cast from acidic and basic solutions

In order to understand the mechanisms behind the undesired aging of films based on vital wheat gluten plasticized with glycerol, films cast from water/ethanol solutions were investigated. The effect of pH was studied by casting from solutions at pH 4 and pH 11. The films were aged for 120 days at 50% relative humidity and 23 degrees C, and the tensile properties and oxygen and water vapor permeabilities were measured as a function of aging time. The changes in the protein structure were determined by infrared spectroscopy and size-exclusion and reverse-phase high-performance liquid chromatography, and the film structure was revealed by optical and scanning electron microscopy. The pH 11 film was mechanically more stable with time than the pH 4 film, the latter being initially very ductile but turning brittle toward the end of the aging period. The protein solubility and infrared spectroscopy measurements indicated that the protein structure of the pH 4 film was initially significantly less polymerized/aggregated than that of the pH 11 film. The polymerization of the pH 4 film increased during storage but it did not reach the degree of aggregation of the pH 11 film. Reverse-phase chromatography indicated that the pH 11 films were to some extent deamidated and that this increased with aging. At the same time a large fraction of the aged pH 11 film was unaffected by reducing agents, suggesting that a time-induced isopeptide cross-linking had occurred. This isopeptide formation did not, however, change the overall degree of aggregation and consequently the mechanical properties of the film. During aging, the pH 4 films lost more mass than the pH 11 films mainly due to migration of glycerol but also due to some loss of volatile mass. Scanning electron and optical microscopy showed that the pH 11 film was more uniform in thickness and that the film structure was more homogeneous than that of the pH 4 film. The oxygen permeability was also lower for the pH 11 film. The fact that the pH 4 film experienced a larger and more rapid change in its mechanical properties with time than the pH 11 film, as a consequence of a greater loss of plasticizer, was presumably due to its initial lower degree of protein aggregation/polymerization. Consequently, the cross-link density achieved at pH 4 was too low to effectively retain volatiles and glycerol within the matrix.     

Crystallinity and structure of starch using wide angle X-ray scattering

Wide angle X-ray diffraction was used to evaluate the crystalline fraction of a variety of starches, using preliminary smoothing then an iterative smoothing algorithm to estimate amorphous background scattering. This methodology was then used to determine initial crystallinity and monitor gelation and retrogradation of high amylose thermoplastic starch used to produce film. Retrogradation was monitored over a 5-day period. It was found that the starch film retrograded rapidly over the first 12 h with the film displaying both B-type crystallinity and long range amorphous ordering that were separately quantitatively calculated. Changes in starch films, including complete or partial gelatinization, retrogradation and crystallinity, were all determined through wide angle X-ray diffraction.