Sustainable biocomposites have been developed by solvent mixing of poly(lactic acid) (PLA) with a fine powder of cocoa bean shells (CBS) and subsequent solution casting, using different concentrations of CBS. The inclusion of CBS recovers the crystallinity of the initially amorphous PLA films and improves the physical properties of the composites. Young's modulus increases by 80% with 75 wt % CBS inclusion; however, the composites maintain plasticity. The barrier properties of the hydrophobic composites were characterized, and the water vapor permeability is found to be ca. 3.5 × 10-5 g·m-1·day-1·Pa-1 and independent of the CBS content. On the other hand, oxygen permeability is found to depend on the CBS content, with values as low as 10 000 mL·μm·m-2·day-1·atm-1 for 50 wt % CBS. Furthermore, CBS confer antioxidant activity to the composites and improve swelling properties rendering the composites biodegradable in aquatic environments, reaching 70% of the maximum biodegradability in just 30 days. The above, in conjunction with the low level of migration measured in food simulant, make the PLA/CBS composites a highly promising material for active food packaging.
Keywords: PLA; active food packaging; barrier properties; biodegradation; bioplastics; cocoa bean; oxygen barrier.