Effect of acetylation of kraft lignin on the blend compatibility with cellulose acetate and the resulting physicomechanical properties

Petroleum-derived single-use plastics have dominated a range of material applications, including packaging and service ware (e.g., water bottles, food containers, and drinking straws). However, despite their short-lived service life, the inherent durability, and stability of these plastics have resulted in significant environmental accumulation and spill, contaminating both aquatic and land ecosystems. Consequently, there is a surging interest in the development of bioplastics as a sustainable alternative to petrochemical derived plastics that align with circular economy principles. Among potential materials, cellulose acetate (CA) showcases impressive mechanical properties, optical characteristics, melt processability, and compostability. However, due to its hygroscopic behavior, inferior barrier properties, and lack of dimensional stability, CA applications in the packaging industry are minimal. In this research, the acetylation of lignin and its use as a functional filler for CA matrix was studied. The impact of varying lignin loadings (up to 30 wt.%) on the tensile, morphological, barrier, and viscoelastic properties of the resulting materials was investigated. A thorough characterization of the compression-molded acetylated lignin-CA films revealed a reduction in water uptake (by 59% over baseline), up to a 41.5% reduction in water vapor permeability, and enhanced tensile properties with melt flowability. In summary, the examined films displayed favorable characteristics for use in food and other packaging applications. Consequently, they serve as low carbon footprint, and eco-friendly substitutes for conventional petrochemical-based packaging materials.