Filler Materials in Package Design

Cell-based cushioning material that combines the protective function of plastic with the sustainability of paper. The material has a flat structure with deformed, curved cells instead of the usual straight walls. It is made by pressing a flat cell structure to deform the cells. The curved walls provide impact protection without losing shape. The material is suitable for packaging, insulation, furniture, sports mats, etc.

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Biaxially oriented polyester film with non-slip surface, transparency, and easy winding for use in packaging applications like food containers and top seals. The film has two layers, A and B, both containing polyethylene terephthalate (PET). The dynamic friction coefficient of the A layer surface, the friction coefficient between A and B layers, and the haze are controlled within specified ranges to balance slipperiness, transparency, and processability. The film's non-slip surface prevents stacked containers from collapsing when pressed together.

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Gas barrier laminate, packaging material, and vacuum insulation material that have excellent gas barrier properties even after folding. The laminate has a specific structure with layers: a polyolefin base layer, a first polyvinyl alcohol (PVA) layer, a vapor deposition layer, and a second PVA layer. The vapor deposition layer is between the two PVA layers. The indentation hardness of the second PVA layer is 0.5 GPa or less. This laminate design provides improved gas barrier performance compared to mono-material polyolefin laminates after folding, which is important for applications like foldable packaging and vacuum insulation.

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Packaging material for roll-fed packaging machines that allows easy folding into packages without compromising sealing integrity. The packaging material has weakening elements on the fin edges. These elements are placed at transverse distances from the fin edges. When folding the material to form packages, the weakening elements guide the material bulging from the fin edges towards them. This prevents bulges forming inside the packages that can compromise sealing.

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Internal packaging material for cushioning and stabilizing objects inside shipping containers to prevent damage from external shocks. The material is designed to fix the packaging object in place while also absorbing impact forces. This provides better protection compared to just using wrapping or boxes. The cushioning material is placed inside the container around the object to absorb shocks that might be transmitted from the outside during transportation.

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A PVDC (polyvinylidene chloride) emulsion for pharmaceutical packaging that provides improved barrier properties, thermal stability, and long-term stability compared to conventional PVDC emulsions. The emulsion is made by using a silica sol as the dispersant instead of traditional surfactants. This avoids issues like decomposition, hydrolysis, migrant formation, crystallization, and poor thermal stability when heating. The silica sol also improves the water vapor barrier performance of the coating. The PVDC emulsion formulation contains 35-50% vinylidene chloride monomer, 0.5-5% comonomer, 0.1-0.5% initiator, 0.01-0.1% stabilizer, 5-7% silane coupling agent modified silica sol, and 30-5

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Biodegradable and compostable polymer compositions for flexible food packaging films that have low water vapor permeability. The compositions contain a mixture of biodegradable polyesters, including rigid polyesters like PBS, PLA, and PHA, as well as flexible polyesters like PBAT and PCL. The compositions also have small amounts of hydrophobic additives like behenamide. The blends have desirable mechanical properties like high modulus, strength, and elongation for packaging applications.

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Laminated films for packaging materials that have excellent retort resistance at high temperatures and impact resistance at high temperatures for applications like retort sterilization. The films have a layered structure with a surface layer, an intermediate layer, and a heat-sealable layer. The surface layer contains a copolymer of ethylene and a monomer like ethyl acrylate or methyl acrylate. The intermediate layer contains a copolymer of ethylene and a monomer like ethyl acrylate, methyl acrylate, or maleic anhydride. The copolymers in the layers have specific compositions and Mw/Mn ratios for balanced retort resistance and impact strength. The layered film structure provides both good retort resistance at high temperatures and impact resistance at high temperatures.

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Retortable packaging film for food products that is recyclable and provides good sealing and tear properties for retort processing. The film uses a mono-polymer laminate of biaxially oriented polypropylene (BOPP) and machine direction oriented polypropylene (MDOPP) instead of multipolymer laminates. A sealing layer with specific polypropylene terpolymer and long-chain branched polyethylene composition provides sealing strength and low melt flow index for retort compatibility. The film has at least 80% polypropylene content.

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Natural fiber-based transparent composites for food packaging that provide a sustainable alternative to fossil fuel-based packaging materials. The composites are made by UV polymerization of alkene and thiol-based monomers with natural fibers like jute. The UV radiation initiates crosslinking reactions to form a tightly bonded matrix around the fibers, resulting in high transparency (>90%) for packaging applications where visibility of contents is essential. The composites offer benefits of natural fiber composites with improved mechanical properties compared to neat polymer films.

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Paper-based packaging film with improved light barrier, moisture barrier, and recyclability for food products like butter and margarine. The film has a paper component, a polymeric film, a metallic flake layer printed on the polymeric film, and a white pigment layer between the metallic flake layer and the paper. The metallic flake layer provides light blocking, the white pigment layer enhances paper appearance, and the adhesive between the layers enables clean separation during recycling. The metallic flake grammage is kept low to balance barrier and recyclability.

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Barrier substrate for packaging containers with excellent gas barrier properties. The barrier substrate is made by coextruding a polyolefin-based stretched film with two resin layers containing polyolefin as the main component and an optional adhesive layer. A vapor deposition film is then applied to the outer surface. The barrier substrate can replace metal-coated substrates for better recyclability. The polyolefin-based barrier has good gas barrier properties and can be used in packaging containers without delamination or corrosion issues when filled with reactive contents.

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Thermoplastic resin film with improved oxygen barrier properties by adding layered minerals to olefin-based resins. The film has a matrix phase made of polyolefin resin and a dispersed phase of flat layered clay minerals. The layered clay minerals peel off to form a maze structure with long axis in film direction. The volume concentration of clay is 1-40%. This configuration provides a labyrinth effect for oxygen barrier without needing lamination or coatings.

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Oxygen and moisture barrier packaging material that uses only polyethylene film to provide sufficient barrier properties. The material consists of layers like stretched polyethylene, blocking layer, adhesive layer, non-stretched polyethylene, and can have additional components like resin barrier layer, heat-resistant layer, and printed layer. The stretched polyethylene provides initial barrier, the blocking layer prevents contaminants from reaching the adhesive, and the adhesive bonds the layers. The non-stretched polyethylene seals the contents. The material allows recycling without reducing yield since all layers are polyethylene.

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Eco-friendly vinyl packaging material that replaces aluminum and starch, decomposes over time, and reduces greenhouse gas emissions when incinerated. The packaging material contains a blend of high-density polyethylene (HDPE), low-density polyethylene (LDPE), biodegradable bionyl, and additives like stearic acid, copper, manganese, zinc, calcium carbonate, softener, and octene. The bionyl includes ethylene vinyl acetate (EVOH), a biodegradable mixed powder, and an oxidative biodegradable catalyst. The packaging is manufactured by extrusion and stretching the blended material. It can be used for food and cosmetics packaging that decomposes over time and reduces environmental impact compared to traditional vinyl.

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Multilayer substrate for packaging materials with improved gas barrier properties and adhesion between layers. The substrate has a stretched polypropylene layer sandwiched between an outer layer and an inner coating layer. The coating layer contains a resin with polar groups to improve adhesion of subsequent layers like vapor deposited films. This prevents delamination and improves gas barrier performance compared to polypropylene-only substrates. The multilayer substrate can be used in packaging applications and the packaging material is made by laminating the substrate with additional layers like vapor deposited films and sealant layers.

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Low opacity, biodegradable, and heat-sealable paper made from cellulose fibers coated with a bio-based wax to reduce opacity and improve barrier properties. The paper has a base sheet of refined softwood cellulose fibers with a basis weight of 10-25 g/m2. It is coated with a transparency agent like a coconut-based wax and a heat-sealable coating like a thermoplastic starch or protein. The coated paper has opacity less than 35% and can be used for packaging without supercalendering.

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Retail packaging solutions that address issues with securing movable product components, protecting complex curved surfaces, and maintaining product positioning during shipping. These solutions include: 1. Removable tear strip between lid and base box that clamps product inside when engaged, leaving a desirable remnant when torn. 2. Collar system for products with movable parts that provides support without constraining motion. The collars conform to the product's shape and connect with interlocking arms to form a closed loop. 3. Non-developable paper protective film for curved surfaces made by molding the paper to match the shape. The film has adhesive on both sides and a central paper layer.

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Recyclable packaging material for dense item packaging applications like pet food bags that can be processed on conventional packaging equipment. The material is a multi-layer structure with a reinforcing layer made of polyethylene textile sandwiched between other polyethylene layers like film and sealant. This allows recyclability since the layers are all polyethylene. The reinforcing layer provides strength and puncture resistance. The layers are adhered together with tie layers.

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Sealant film for packaging applications that enables recycling of mixed resin materials. The film has a layer containing recycled material with two or more resin types, followed by a separate sealant layer. The recycled layer has small, localized regions with lower transmission compared to the surrounding. These regions have maximum area and aspect ratio limits to prevent clumping. This allows recycling mixed resins while maintaining sealant and mechanical properties.

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Coating packaging materials like paper and cardboard with a thixotropic aqueous mixture to improve barrier properties like reducing gas and moisture transfer through the material. The coating composition contains smectite clay, a water-soluble polymer, and a cross-linking agent that links the clay to the polymer. Applying the mixture to a surface and heat treating crosslinks the clay-polymer barrier. This provides coated packaging with improved barrier properties for replacing single-use plastic in produce shipping.

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Pulp mold packaging with improved strength, insulation and stackability for fresh product transportation. The packaging has a main body with a cover that attaches inside the main body. This allows for insulation between the main body and cover. The cover has a top and bottom mold with an internal space. The main body has a top mold with an internal space. The cover and main body molds are made of pulp material with a binder, antifoaming agent, and water repellent. Grooves on the molds prevent distortion. A fixed coupling connects the cover bottom to the main body. This prevents jamming when stacked. The internal spaces between the molds can be filled with cellulose foam insulation.

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Laminate sheet and food packaging container with reduced variation in hiding power when filled with a high percentage of inorganic powder. The laminate sheet has a three-layer structure with an inner layer containing the inorganic powder, and outer layers without the powder. The powder particle size distribution is optimized: D20 2.0-3.4 μm, D50 4.8-7.6 μm, D70 7.7-11.6 μm. The inner layer has higher powder content than the outer layers. The powder content is 40-80% by mass of the laminate sheet. The outer layer thickness ratio is 2-20% of the total sheet thickness. This configuration suppresses hiding power variation when producing sheets with high inorganic powder content.

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Laminated sheet and food packaging container with reduced hiding variation when filled with a high content of inorganic powder. The laminate sheet has a specific particle size distribution for the inorganic powder, with D20 of 2.0-3.4 μm, D50 of 4.8-7.6 μm, and D70 of 7.7-11.6 μm. The inner layer contains more inorganic powder than the outer layers. The thickness ratio of the outer layers is 2-20%. This reduces hiding powder variation during mass production. The laminate sheet can be used for food packaging containers.

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Packaging with improved stackability and resistance to bursting and top load forces for products like tubes, bottles, cans, and cartridges made from materials with low cohesion like cellulose. The improvement is achieved by confining the end of the tubular body between fixed elements on the inside and outside. This assembly technique prevents the low cohesion material from separating during stacking or internal pressure, improving stackability and burst resistance. The fixed elements can have low cohesion materials like cellulose too.

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Bag for packaging fruits and vegetables that prevents mold growth and spoilage without sacrificing visibility of the contents. The bag has a first region made of a polylactic acid (PLA) film and a second region made of a paper sheet. The paper sheet can be a laminate with a resin layer. The paper sheet basis weight is 100 g/m2 or less. The PLA film density is 1.0 g/cm3. The regions are bonded by heat sealing or an adhesive. This configuration using PLA film and paper inhibits mold growth better than just PLA film alone. The paper prevents mold while allowing visibility.

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Eco-friendly laminated film for packaging applications that maintains barrier properties and bonding strength after heat sterilization. The film has layers: an outermost stretched PP film, a barrier coating of modified PVA, an adhesive layer, an inner stretched PP film, and a heat seal layer of unstretched PP with lower melting point than the outermost layer. The barrier coating contains modified PVA crosslinked with organosilane compounds. The inner PP film has a lower melting point than the outermost film. This configuration allows the film to retain gas barrier and adhesion after heat sterilization.

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Barrier-coated cellulose-based fibrous substrate for use in oxygen-sensitive packaging materials like cartons for liquid foods. The substrate has a cellulose base with a steam-resistant coating and an oxygen barrier coating applied by dispersion coating and drying. The cellulose substrate density is 700-800 kg/m3 and grammage 30-80 g/m2 for good porosity. The steam coating contains inorganic particles and polymer binder. This improves adhesion for the oxygen barrier coating. The substrate provides oxygen barrier in laminated packaging materials.

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Eco-friendly internal packaging material made from a biocomposite of mycelium, pine needles, wheat straw, and wood powder. The composite is reinforced with pine needles and grown using Pleurotus ostreatus mycelium. It provides cushioning and protection for fragile items like electronics while being fully biodegradable. The composite is made by inoculating the substrate with mycelium, sterilizing, growing, and heat treating to cure.

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Thermally insulated, waterproof, and high-strength packaging bag that provides improved protection for goods while reducing wrinkling and damage. The bag uses a composite structure with outer and inner paper layers sandwiched between insulating foam layers. Elastic adhesive is used to bond the layers. The outer layer has a convex buffer structure that disperses pressure. The insulating foam has a gradient height convex structure to prevent wrinkling. The adhesive is a polyurethane emulsion with thickener, wetting agent, and silane coupling agent for strength and elasticity.

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A biodegradable packaging material made from chicken feathers and a biodegradable polymer called polybutylene adipate terephthalate (PBAT). The process involves extracting keratin from chicken feathers and combining it with PBAT to create a biodegradable composite film for packaging applications. The goal is to replace conventional plastics with a sustainable and compostable alternative that reduces waste and environmental impact.

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Recyclable packaging material with improved strength, heat resistance, and barrier properties. The packaging material is made by laminating a stretched polyolefin film with a gas barrier layer and a polyolefin layer, and then heat sealing it. The key innovation is using the same polyolefin material for both the substrate and the heat seal layer. This allows recycling the material by separating the polyolefin layers. The stretched polyolefin layer improves strength. The gas barrier layer provides containment. The laminate structure enables recycling by separating the polyolefin layers.

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Biodegradable nanocomposite food packaging films that provide enhanced antimicrobial and oxidation inhibition properties to prevent spoilage and pathogen growth. The films are made by incorporating biosynthesized zirconium nanoparticles capped with a bioactive compound called Arachisan derived from peanut leaves. The ArZrNPs provide antimicrobial activity against food-borne pathogens like Salmonella and E. coli. They also scavenge free radicals to prevent oxidation. The nanoparticles are dispersed in biodegradable polymer films for sustainable packaging with extended shelf-life and reduced pathogen risk.

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Eco-friendly and biodegradable packaging materials made from sugarcane bagasse that are sustainable, flame retardant, mechanically robust, thermally stable, and have low environmental impact compared to plastic alternatives. The process involves delignifying the bagasse, phosphorylating it, homogenizing, sonicating, casting, freezing, and freeze-drying to create films, aerogels, boards, boxes, plates, and sheets. The phosphorylation step enhances the properties like solvothermal stability, degradation resistance, and flame retardancy.

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Blow molded bottle container with improved thin-wall thickness, drawdown resistance, and burr removal properties. The container has a specific ratio of bio-based polyethylene, high density polyethylene, and linear low density polyethylene. The ratio of bio-based polyethylene to total polyethylene is 20-50%. The ratio of (bio-based + high density):linear low density polyethylene is 40:60 to 60:40. This composition allows thin-walled containers with reduced deformation and burr retention compared to conventional containers. The thin-walled containers have better drawdown resistance and easier burr removal during molding.

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Hybrid biocomposite film for food packaging that combines whey protein isolate, chitosan, and silica to improve properties like strength and antibacterial activity. The film consists of a whey protein isolate matrix with added chitosan and silica fillers. The chitosan provides antimicrobial properties while the silica increases strength. The composite films have higher tensile strength and elongation compared to the whey protein isolate film. The chitosan concentration of 1.5% and silica concentration of 5% provide optimal antibacterial properties against E. coli.

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High-strength packaging bag with improved heat insulation, water resistance, and compression resistance compared to conventional bags. The bag has a composite structure with outer and inner layers sandwiched between insulating layers. The outer and inner layers provide strength and compressive resistance, while the insulating layers prevent air flow and moisture. Adhesive layers connect the layers. The adhesive is a polyurethane emulsion with tackifiers, impregnating agents, and silane coupling agents for stability and dispersion.

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Eco-friendly cushioning packaging material made from natural pulp like sugarcane and bamboo instead of plastic or wood pulp. The packaging material is manufactured by processing paper made from the natural pulp. To reduce dust generation from the short fibers of sugarcane pulp, a small amount of bamboo pulp is added during fabric production. The paper surface is coated with starch and biodegradable wax to improve strength and water resistance. This allows replacing traditional plastic cushioning materials with a more sustainable option that reduces plastic usage, carbon emissions, and environmental pollution.

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Biodegradable, antibacterial, and antioxidant food packaging film made from natural materials like sodium alginate, egg white, and black seed oil. The film is prepared by mixing the polymers and oil in water, forming a hydrogel, and then freeze-thaw cycling to improve uniformity. The film provides extended shelf life and nutrition preservation for perishable produce by preventing spoilage from bacteria and oxidation. The biodegradable packaging can be disposed of without processing.

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Biodegradable food packaging film made from natural polymers like guar gum, agar-agar, and beeswax. The film has excellent oxygen barrier properties to maintain freshness and shelf life of food products. It also has low water vapor permeability, good mechanical strength, and contact angle greater than 90 degrees. The biodegradable film reduces environmental impact compared to traditional plastic packaging. The film is prepared by dissolving guar gum and agar-agar in water, adding beeswax, and spreading the solution onto a substrate to dry into the film.

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Bioplastics made from agricultural waste like mango seeds, filled with chitosan or nanochitosan, for use as sustainable food packaging. The bioplastics have improved properties like reduced water vapor transmission, better mechanical strength, and antimicrobial activity compared to the pure mango seed bioplastic. The chitosan and nanochitosan fillers also reduced water uptake. The recommended bioplastics for food packaging are 20% CS-30% Sor-10% CA and 30% NCS-20% Sor-10% CA.

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A food-grade barrier coating for molded pulp products like bowls, trays, and containers that provides water and grease resistance. The coating is made by crosslinking shellac resin applied to the pulp. The crosslinking involves thermal aging in an oven to melt and fuse the shellac chains. This creates a durable, water-repellent coating that penetrates the pulp fibers. The coated pulp products have low cobb (water absorption) and kit (grease penetration) values, making them suitable for food packaging. The crosslinked shellac barrier meets food migration limits at elevated temperatures.

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A sustainable and biodegradable packaging material made from coating chitosan on dry banana leaves. The method involves spreading a chitosan-glycerol solution onto a banana leaf, letting it dry, and repeating on the other side. This creates a flexible, smooth, and biodegradable packaging material that can be used for food items. The chitosan coating provides strength and moisture barrier properties, while also degrading completely in soil within 15 days.

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Food packaging material with improved hiding properties and recyclability compared to transparent packaging. The material uses an opaque adhesive layer sandwiched between transparent films. The opaque adhesive is made by mixing a urethane adhesive with ink pigments. This opaque layer prevents colors from transferring between the films and improves hiding properties. The transparent films can be recycled separately from the opaque adhesive. The adhesive formulation uses specific ink pigment, solvent, and dispersant amounts to optimize adhesion and opacity.

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Biodegradable and compostable bioplastic packaging made from local agricultural materials like fibers, oils, and essential oils. The packaging is cheap, biodegradable, and active due to the incorporation of essential oils. The process involves converting agricultural fibers like raffia, sisal, and pineapple into cellulose acetate. This is mixed with polylactic acid, edible oils, and essential oils, homogenized, and dried into film.

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Recyclable flexible packaging film with improved barrier properties by using a specific multilayer structure and processing method. The film has two separated ethylene vinyl alcohol (EVOH) barrier layers sandwiched between polyolefin layers. This structure provides good gas barrier without needing a high EVOH content that would prevent recycling. The film is also machine direction oriented (MDO) to further enhance barrier performance. The MDO process involves blowing the film, collapsing it, and then stretching it in the machine direction. This compresses the layers together for better barrier sealing.

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Biodegradable starch-based polymer composition with ionic liquid plasticizers for sustainable packaging. The composition involves blending native starch, biodegradable polyester, and an ionic liquid plasticizer to create a thermoplastic starch film that is stable under varying humidity conditions and has improved mechanical properties compared to traditional starch blends. The ionic liquid plasticizer prevents retrogradation and maintains stability even after storage. The composition offers an eco-friendly alternative to synthetic plastics for packaging applications.

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Biodegradable food packaging films made from gelatin with added copper and zinc oxide nanoparticles that have enhanced physical stability and antimicrobial properties compared to plain gelatin films. The nanoparticles crosslink with the gelatin to improve moisture resistance, strength, and durability for food packaging applications. The copper and zinc ions released from the nanoparticles also have antibacterial effects to prevent microbial contamination on food surfaces.

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Biodegradable food packaging material made from natural components like plant extracts, graphene oxide, and calcium carbonate. The packaging has layers of paper, adhesive, and a coating. The base layer is made from a copolymer resin, polyethyleneimine, calcium carbonate, tourmaline powder, and plant extract. The adhesive layer contains PLA, lactic acid oligomer, PBAT, tetraethylene glycol diacrylate, sisal fiber, mineral oil, and plant oil. The coating layer is made from polyurethane acrylate resin, PLA, graphene oxide, plant extract, and plant oil. The packaging provides improved biodegradability, reduced oxygen permeability, and antibacterial function compared to conventional plastic packaging.

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Biodegradable packaging cushioning material that is environmentally friendly, has low manufacturing costs, and improves moisture resistance, impact resistance, and shrinkage resistance compared to traditional starch-based foam cushioning materials. The composition contains starch, biodegradable aliphatic polyester, foam cell structure improver, foaming nucleating agent, and lubricant. The composition is mixed and extruded through a twin screw extruder with controlled water injection to create the foam. This allows manufacturing a biodegradable cushioning material with improved properties compared to powder-based starch foams.

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