Polyhydroxyalkanoate coatings restrict moisture uptake and associated loss of barrier properties of thermoplastic starch films

This work investigates the use of polyhydroxyalkanoate (PHA) films as moisture barriers for thermoplastic starch (TPS) films, to produce biodegradable, multi-layer materials with high gas barrier properties. This is a necessary extension to the limited work available on this topic and confirms that PHAs are suitable coating materials for TPS films intended for use in food packaging. Under storage conditions of up to 75% relative humidity (RH) for 2 weeks, a PHA coating maintained the moisture content (MC) of the TPS below the point at which its barrier properties were detrimentally affected. Furthermore, for PHBV coating thicknesses of 91–115 μm, the MC of the TPS remains significantly lower than uncoated TPS for the duration of the experiment (>25 days). The flux of water into the coated TPS fit to a model based on Fick's law. However, when the multi-layered films were stored at 95% RH delamination occurred within 24 h. Preliminary investigation into possible material design improvements showed that the addition of a small amount of PHA to the TPS layer prolonged the time to delamination.