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Development of a Continuous Extrusion Process for Alginate Biopolymer Films for Sustainable Applications.

Zahra Eslami1,2, Saïd Elkoun1,2, Miraidin Mirzapour1,2

  • 1Center for Innovation in Technological Ecodesign (CITE), University of Sherbrooke, Sherbrooke, QC J1K 2R1, Canada.

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|July 12, 2025
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Summary

This study introduces a new thermo-mechanical method for creating extrudable alginate films. Optimizing glycerol content and processing temperature is key for developing advanced, sustainable packaging materials.

Keywords:
alginateextruderglass transition temperaturemechanical propertiesplasticizer

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Area of Science:

  • Materials Science
  • Polymer Science
  • Biomaterials Engineering

Background:

  • Conventional solvent-casting for alginate films has limitations in scalability.
  • There is a growing need for sustainable and bio-based packaging solutions.
  • Understanding the impact of processing parameters on alginate film properties is crucial for industrial application.

Purpose of the Study:

  • To develop a novel, scalable method for producing extrudable alginate-based films using continuous thermo-mechanical mixing.
  • To investigate the effects of glycerol concentration and processing temperature on the thermal, mechanical, and structural properties of these films.
  • To provide insights into optimizing the formulation and production of bio-based packaging materials.

Main Methods:

  • Continuous thermo-mechanical mixing for film production.
  • Systematic variation of glycerol concentration (30-50 wt%) and processing temperature (110-120 °C).
  • Structural characterization using 1H NMR and FT-IR.
  • Thermal analysis via Differential Scanning Calorimetry (DSC) and Dynamic Mechanical Analysis (DMA).
  • Modeling of glass transition temperature (Tg) using the Gordon-Taylor equation.

Main Results:

  • Glycerol incorporation significantly reduced Tg (up to 76 °C with 40 wt% glycerol) and enhanced film ductility and toughness (up to 3.26 MJ/m³).
  • Processing temperature effects on Tg and elongation at break were dependent on glycerol content, with potential thermal degradation at lower plasticizer levels.
  • Films with higher glycerol content exhibited stable thermal and mechanical properties across tested temperatures.
  • This study is among the first to examine processing temperature effects on extruded, plasticized pure alginate films.

Conclusions:

  • Continuous thermo-mechanical mixing offers a scalable alternative for producing extrudable alginate films.
  • Optimizing glycerol concentration and processing temperature is essential for tailoring alginate film properties for specific applications, particularly in bio-based packaging.
  • The findings contribute to the development of advanced, sustainable materials by elucidating critical formulation and processing-structure-property relationships.