Melt processing of biodegradable poly(lactic acid)/functionalized chitosan nanocomposite films: mechanical modeling with improved oxygen barrier and thermal properties

The present work demonstrates about the formulation of functionalized chitosan (CH-g-OLLA) through the transformation of hydrophilic nature of chitosan into hydrophobic by grafting with oligo(L-lactic acid) (OLLA). The developed CH-g-OLLA is easily soluble in poly(lactic acid) (PLA) matrix, which provides an opportunity towards producing industrially viable nanocomposite films for stringent food packaging and beverages applications. The grafting of OLLA chains is confirmed at NH₂ group of chitosan through the presence of two new peaks at 4.2 and 5.1 ppm in ¹H–NMR spectra. Various parameters like yield (%), grafting efficiency (%) and percent grafting (%) are calculated as ~51.6, ~40 and ~150%, respectively. Functionalized chitosan has been utilized as nano-filler in PLA matrix to fabricate PLA/CH-g-OLLA nanocomposite films which have compounded successfully by co-rotating twin screw compounder cum cast film extrusion technique (distinctly advantageous over conventional solution casting) at bench scale as well as semi-pilot scale and further demonstrated for its application in the area of food packaging with tailored oxygen barrier properties. Uniform dispersion of spherical aggregates of functionalized chitosan is observed in PLA/CH-g-OLLA nanocomposite films using TEM analysis. A significant reduction up to ~11 °C in glass transition temperature of PLA is observed by adding 5 wt% of nano-filler as a result of plasticization effect, which is an essential property in designing of flexible packages. Mechanical modeling of extruded PLA/CH-g-OLLA films has been performed to compare the experimental values with theoretical results using various mathematical models in which modified foam model, Nielsen model and modified Mitsuishi model demonstrate the best match for Young’s modulus (±0.08), tensile strength (±0.06) and percentage elongation (±0.03), respectively. This may be a significant contribution towards commercialization of such formulation where elegant melt extrusion process of PLA with functionalized chitosan is capable of reducing oxygen permeability up to ~10 folds due to a drastic reduction (~96%) in oxygen solubility.