Opportunities and Challenges in the Application of Bioplastics: Perspectives from Formulation, Processing, and Performance.

Tremendously negative effects have been generated in recent decades by the continuously increasing production of conventional plastics and the inadequate management of their waste products. This demands the production of materials within a circular economy, easy to recycle and to biodegrade, minimizing the environmental impact and increasing cost competitiveness. Bioplastics represent a sustainable alternative in this scenario. However, the replacement of plastics must be addressed considering several aspects along their lifecycle, from bioplastic processing to the final application of the product. In this review, the effects of using different additives, biomass sources, and processing techniques on the mechanical and thermal behavior, as well as on the biodegradability, of bioplastics is discussed. The importance of using bioplasticizers is highlighted, besides studying the role of surfactants, compatibilizers, cross-linkers, coupling agents, and chain extenders. Cellulose, lignin, starch, chitosan, and composites are analyzed as part of the non-synthetic bioplastics considered. Throughout the study, the emphasis is on the use of well-established manufacturing processes, such as extrusion, injection, compression, or blow molding, since these are the ones that satisfy the quality, productivity, and cost requirements for large-scale industrial production. Particular attention is also given to fused deposition modeling, since this additive manufacturing technique is nowadays not only used for making prototypes, but it is being integrated into the development of parts for a wide variety of biomedical and industrial applications. Finally, recyclability and the commercial requirements for bioplastics are discussed, and some future perspectives and challenges for the development of bio-based plastics are discussed, with the conclusion that technological innovations, economic incentives, and policy changes could be coupled with individually driven solutions to mitigate the negative environmental impacts associated with conventional plastics.