Efficient Production of Mechanically Recyclable and Compostable Blown Films of Thermoplastic Starch/Poly(Butylene Succinate-Co-Adipate) Blends

Journal article, 2026

Sustainable bio-based and biodegradable materials are receiving increased attention in response to the environmental impact of conventional non-biodegradable plastics. Thermoplastic starch (TPS) and poly(butylene succinate-co-adipate) (PBSA) are bio-based and biodegradable materials that have the potential to serve as an alternative solution in the disposable packaging sector. The melt processing of TPS is, however, challenging due to its moisture sensitivity and rapid aging. This study investigates the development of TPS/PBSA blends without compatibilizers, comparing a conventional two-step processing method with a one-step approach combining starch plasticization and its blending with PBSA. The one-step process exhibits higher stability, making it a promising candidate for industrial applications due to its reduced energy consumption and production costs. To contribute to waste reduction, disintegration in industrial composting and multiple cycles of mechanical recycling were performed.