Carvacrol encapsulation by electrospinning or solvent casting to obtain biodegradable multilayer active films for food packaging applications

Resumen

The massive use of synthetic plastics and their environmental impact makes necessary the search for biodegradable alternatives for food packaging. Likewise, the need to increase the shelf life of food has aroused great interest in the development of active materials (antimicrobial and antioxidant) that maintain food quality and safety for longer periods of time through the use of compounds of natural origin, safe for the consumer. In this sense, the development of active biodegradable materials for food packaging is both a major imperative and challenge for the food industry today. In the present Doctoral Thesis, the encapsulation of carvacrol has been studied by means of the electrospinning or casting of different polymeric solutions with carvacrol. Biodegradable polymers with different polarities (thermoplastic starch: TPS, poly(vinyl-alcohol): PVA, poly-(¿-caprolactone): PCL or poly(lactic acid): PLA) dissolved in the appropriate solvent have been used to obtain active layers. These have been combined with other polymers with complementary properties, to obtain active laminates suitable for food packaging. The laminates combined polar polymers (TPS or PVA) and non-polar polyesters (PCL or PLA) incorporating carvacrol in one of the layers. The release kinetics of the active ingredient was evaluated, as well as the antimicrobial action of the materials obtained. The laminates were characterized in their functionality as a packaging material (barrier, mechanical or optical properties), as well as in their structure and thermal behaviour. Encapsulation studies revealed a higher encapsulating potential of carvacrol for non-polar polymers (PCL and PLA), although PVA also showed a good affinity with the active compound. The PVA matrix showed a higher retention of carvacrol by electrospinning of its aqueous solutions than by casting, without the need for addition of surfactants such as Tween 85. For the encapsulation in PLA, binary mixtures of solvents suitable for food contact (ethyl acetate and DMSO) were used. A higher encapsulation efficiency of PLA was obtained in the materials produced by casting than by electrospinning. The carvacrol release kinetics of PCL fibres explained the higher antibacterial effect against Escherichia coli and the lower antilisterial effect. The release ratio of the active ingredient increased when the polarity of the food simulants decreased, showing a complete release in non-polar systems and only up to 75% in aqueous systems that would require a higher proportion of the active ingredient in the packaging material to enhance its effectiveness. The combination of TPS films with carvacrol loaded PCL fibres resulted in materials with improved water vapour permeabilities, compared to starch films, with no relevant effects on the other functional properties. When the laminates were tested in vitro against Gram (+) and Gram (-) strains, they showed a similar antibacterial effect to that of PCL fibres with carvacrol, but delayed in time. Disintegration-biodegradation studies of PCL-starch laminates revealed that carvacrol films affected the activity of the compost inoculum, slightly decreasing the biodegradability of the laminates, but reaching similar disintegration values (75-80%) to the carvacrol-free samples. PLA and PVA laminates were also obtained by casting aqueous PVA solutions with carvacrol. The surface of PLA was submitted to aminolization in order to improve the extensibility of the aqueous solutions. Despite the increase in the polar component of the PLA surface energy and its improved wettability with PVA solutions, these bilayers did not show significant improvement in mechanical and barrier properties over the PLA monolayers.