Extrusion-blown starch/PBAT biodegradable active films incorporated with high retentions of tea polyphenols and the release kinetics into food simulants

To reduce thermal degradation of tea polyphenols (TP) in final active packaging materials, poly(butylene adipate-co-terephthalate) (PBAT), starch, plasticizer, and TP were directly synthesized into masterbatches by one-pot method in this study without pre-dispersion, and then blown into active films. TP interacted with starch through hydrogen bonds, with little interaction with PBAT. Barrier properties were improved by incorporating TP into the films, whereas mechanical properties slightly decreased. Blending starch into PBAT greatly accelerated the degradation of the film. And the incorporation of TP slowed down the short-term degradation of the starch/PBAT film, but accelerated the long-term degradation. The initial total polyphenol content in the active film was positively related to the TP loading, whereas the initial retention rate remained above 95 % regardless of TP loadings. The retention rate of TP in active films decreased with storage time, but it was still above 80 % after 12 months, with a favorable stability. TP-loaded films displayed efficient antioxidant and antimicrobial activities with strong dose dependence. The release of TP into food simulants was mainly induced by random diffusion, with little effect from polymer swelling. The short-term release kinetics was well described by Fick's second law. This work has demonstrated the feasibility of TP being incorporated into the active films with high retention through high-throughput fabrication, which provides formula and technical options for the industrial development of active packaging materials.