The use of biopolyesters, as polymeric matrices, and natural fillers derived from wastes or by-products of food production to achieve biocomposites is nowadays a reality. The present paper aims to valorize mussel shells, 95% made of calcium carbonate (CaCO3), converting them into high-value added products. The objective of this work was to verify if CaCO3, obtained from Mediterranean Sea mussel shells, can be used as filler for a compostable matrix made of Polylactic acid (PLA) and Poly(butylene adipate-co-terephthalate) (PBAT). Thermal, mechanical, morphological and physical properties of these biocomposites were evaluated, and the micromechanical mechanism controlling stiffness and strength was investigated by analytical predictive models. The performances of these biocomposites were comparable with those of biocomposites produced with standard calcium carbonate. Thus, the present study has proved that the utilization of a waste, such as mussel shell, can become a resource for biocomposites production, and can be an effective option for further industrial scale-up.

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In this work, processability and mechanical performances of bio-composites based on poly(3-hydroxybutyrate-co-3-hydroxyvalerate) (PHBV) containing 5, 10, and 15 wt % of bran fibers, untreated and treated with natural carnauba and bee waxes were evaluated. Wheat bran, the main byproduct of flour milling, was used as filler to reduce the final cost of the PHBV-based composites and, in the same time, to find a potential valorization to this agro-food by-product, widely available at low cost. The results showed that the wheat bran powder did not act as reinforcement, but as filler for PHBV, due to an unfavorable aspect ratio of the particles and poor adhesion with the polymeric matrix, with consequent moderate loss in mechanical properties (tensile strength and elongation at break). The surface treatment of the wheat bran particles with waxes, and in particular with beeswax, was found to improve the mechanical performance in terms of tensile properties and impact resistance of the composites, enhancing the adhesion between the PHBV-based polymeric matrix and the bran fibers, as confirmed by predictive analytic models and dynamic mechanical analysis results.

The potential use of paper sludge (PS) as filler in the production of bio-composites based on poly lactic acid (PLA) and polybutylene adipate terephthalate (PBAT) was investigated. PS/PLA/PBAT composites, with addition of acetyl tributyl citrate (ATBC) as biobased plasticizer, were produced with PS loadings up to 30 wt.% by twin-screw extrusion followed by injection moulding. The composites were characterized by rheological measurements, thermogravimetric analysis (TGA), differential scanning calorimetry (DSC) and mechanical tests (tensile and impact resistance) to study the effect of PS on the processability, thermal stability, crystallinity and mechanical performance of polymeric matrix. The optimized composites at higher PS content were successfully processed to produce pots for horticulture and, in view of this application, preliminary phytotoxicity tests were conducted using the germination test on Lepidium sativum L. seeds. Results revealed that developed composites up to 30 wt.% PS had good processability by extrusion and injection moulding showing that PS is a potential substitute of calcium carbonate as filler in the production of bio-composites, and the absence of phytotoxic effects showed the possibility of their use in the production of pots/items for applications in floriculture and/or horticulture.

The increase in the world’s economic growth and global population requires a more efficient management of the Earth’s natural resources. The combined plastic and food sector forms an important part of the EU economy, accounting for 15 million jobs. Unlocking the innovation potential in the field of packaging and cosmetics will significantly contribute to job creation and competitiveness. Sustainable synthesis of polyhydroxyalkanaotes from agro-food by-products as well as synthesis of lactic acid co-polymers constitute a pathway to achieving sustainable polymeric matrices. Natural fibers, as well as polysaccharides (starch, cellulose, chitin, chitosan), cutin, and protein rich by-products, are abundantly available from the agro-food industry. Natural fibers may be modified chemically with enzymes or by treating their surface with natural waxes, with a significant improvement in adhesion and impact resistance. An overview on the availability, collection, treatment, and approach of valorization of largely available agro-food waste biomass for both polymer and biocomposite production is hereby reported, with examples of case studies and product developed in our research units, such as sustainable pots, rigid containers, active films, and non-woven tissue.