Improving paper-based packaging with home compostable modified starch coatings: a focus on heat seal optimization

In the quest for sustainable packaging solutions, this study pioneers the development of home-compostable coatings that transform the heat sealability of paper-based flexible food packaging—a longstanding challenge in the industry. Leveraging sodium starch octenyl succinate (SSOS) and maltodextrin (MAL), compostable starch derivatives, combined with sorbitol (SOR) and glycerol (GLY) as plasticizers, we optimized critical sealing parameters: seal initiation temperature (SIT) and fiber tear temperature (FTT). Using an innovative central composite design (CCD) and response surface methodology (RSM), the research reveals the interplay between material composition and sealing performance, uncovering unprecedented efficiency in achieving low SIT and FTT values. Remarkably, the optimal formulations achieved SIT and FTT values as low as 120 °C and 147 °C for SSOS (10 % SOR, 20 % GLY) and 112 °C and 125 °C for MAL (20 % SOR, 5 % GLY), outperforming traditional alternatives while maintaining full compostability. The statistical framework demonstrated exceptional predictive accuracy (R2 > 0.85) and precision (CV < 7.4 %), underscoring the reliability and scalability of these formulations. This groundbreaking approach bridges the gap between sustainability and functionality, setting a new standard for home compostable packaging materials. By providing a scalable pathway to reduce environmental impact without compromising performance, this study offers transformative insights for the packaging industry and positions itself as a cornerstone for future innovations in sustainable food packaging.