Assessing PLA/PBSA Films for Sustainable Packaging for Moist and Perishable Foods

The environmental impact of petroleum-based plastics has accelerated the search for sustainable alternatives in food packaging. Polylactic acid (PLA), a biobased and compostable polymer, is among the most promising candidates, yet its inherent brittleness and poor moisture barrier limit its application in high-humidity contexts such as dairy packaging. This study investigates immiscible PLA/poly(butylene succinate-co-adipate) (PBSA) blend films as potential biobased packaging materials for perishable foods. Even if these blends have been already studied, limited attention has been given to the systematic characterization of the baseline barrier properties of unmodified PLA/PBSA blends in contact with liquid dairy products. Four blend ratios (PLA/PBSA = 30/70, 40/60, 50/50, 60/40 wt%) were prepared via micro-compounding and compression molding. The films were characterized through melt flow analysis, FTIR, SEM, DSC, DMTA, and tensile testing to evaluate their thermal, morphological, and mechanical properties. Crucially, moisture barrier performance was assessed under simulated dairy conditions by sealing fresh whey at 4 °C and monitoring weight loss over 30 days. Results revealed that while tensile strength and storage modulus (E') decreased nearly linearly with increasing PBSA content, elongation at break exhibited a non-linear trend, highlighting the complex interplay between blend morphology and mechanical behavior. The study provides a baseline understanding of neat PLA/PBSA blends in contact with liquid dairy, identifying the most promising formulations for future scale-up. These findings contribute to the development of biodegradable packaging systems tailored for refrigerated, high-moisture food applications.