FIELD OF INVENTION

The present disclosure relates to a process for preparing a modified starch composition. Specifically, the present disclosure relates to a process for preparing a modified starch composition comprising starch and a compatibilizing agent.

BACKGROUND

Biodegradable materials and environmentally friendly alternatives for plastic are increasingly being adopted in various industries, including for example packaging. Starch is easily available, renewable, biodegradable and generally low cost and has been used for preparing biodegradable plastics. However, starch films are brittle and starch, a hydrophilic material, tends to deteriorate on exposure to humidity. These factors make starch unsuitable for preparing biodegradable plastics especially for food packaging.

To overcome such limitations, starch is modified and blended with other polymers. Modification of starch includes for example plasticization and gelatinization that weaken the inter-molecular hydrogen bonding of the starch molecule.

Basiak, Ewelina et al. “How Glycerol and Water Contents Affect the Structural and Functional Properties of Starch-Based Edible Films” Polymers vol. 10,4 412. 8 Apr. 2018, discloses modification of starch using 30% and 50% w/w of glycerol. However, Basiak discloses that such modified starch is highly soluble in water (solubility > 30%). When such modified starch is blended with other biodegradable polymers, the resultant polymer composition demonstrates poor mechanical properties at higher percentage of starch.

SUMMARY

The present disclosure relates to a process for preparing a modified starch composition. Said process comprises preparing a blend comprising starch and a compatibilizing agent, wherein the blend comprises starch and the compatibilizing agent in a molar ratio of 2:1; and wherein the blend comprising starch and the compatibilizing agent is prepared without the addition of water; processing the blend comprising starch and the compatibilizing agent in a twin-screw processor at a barrel temperature ranging between 60-110°C; and obtaining the modified starch composition from the twin-screw processor.

BRIEF DESCRIPTION OF DRAWINGS

Figure 1 shows a comparative study of the solubility of the modified starch composition prepared in accordance with an embodiment of the present disclosure.

Figure 2 shows a comparative study of the solubility of the modified starch composition prepared in accordance with an embodiment of present disclosure vis-a-vis conventional cast film, in water at various temperatures.

Figure 3 shows the thermogravimetric analysis of the modified starch composition, prepared in accordance with an embodiment of the present disclosure.

DETAILED DESCRIPTION

For the purpose of promoting an understanding of the principles of the disclosure, reference will now be made to embodiments and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the disclosure is thereby intended, such alterations and further modifications in the disclosed composition and method, and such further applications of the principles of the disclosure therein being contemplated as would normally occur to one skilled in the art to which the disclosure relates.

It will be understood by those skilled in the art that the foregoing general description and the following detailed description are exemplary and explanatory of the disclosure and are not intended to be restrictive thereof. Reference throughout this specification to “one embodiment”, “an embodiment” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. Thus, appearances of the phrase “in one embodiment”, “in an embodiment” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment.

The terms “a,” “an,”, and “the” are used to refer to “one or more” (i.e. to at least one) of the grammatical object of the article.

The terms "comprises", "comprising", or any other variations thereof, are intended to cover a non-exclusive inclusion and are not intended to be construed as “consists of only”, such that a process or method that comprises a list of steps does not include only those steps but may include other steps not expressly listed or inherent to such process or method.

Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. Although any methods and materials similar or equivalent to those described herein can be used in the practice or testing of the disclosure, the preferred methods, and materials are now described.

“Solubility index” as stated herein refers to a measurement of the solubility of the modified starch composition in a given solvent. It is calculated as a percentage of the original weight of the sample, for instance, the water solubility index (WSI) is expressed as:

WSI (%) = Weight of dissolved solid in water x 100 Weight of dry solids.

The present disclosure relates to a process for preparing a modified starch composition. Said process comprises preparing a blend comprising starch and a compatibilizing agent, wherein glucose in starch and the compatibilizing agent has a molar ratio of 2: 1 ; and wherein the blend comprising starch and the compatibilizing agent is prepared without the addition of water; processing the blend comprising starch and the compatibilizing agent in a twin-screw processor at a barrel temperature ranging between 60-110°C; and obtaining the modified starch composition from the twin-screw processor.

The obtained modified starch composition comprises starch and the compatibilizing agent in a w/w ratio of 2: 1-4:1, wherein the modified starch composition has a solubility index of less than 15% in water at a temperature of about 80°C, and wherein thermogravimetric analysis of the modified starch composition shows in the thermogram a characteristic peak in the range of 120°C to 180°C. The process conditions as well as the ratio of starch and the compatibilizing agent disclosed herein provide mechanical and thermal interaction such that a modified starch is obtained which is substantially insoluble in cold water, water at room temperature as well as chloroform.

In accordance with an aspect, the obtained modified starch composition is insoluble in cold water. Cold water refers to water maintained at a temperature of about 10°C.

In accordance with an aspect, the obtained modified starch composition has a solubility index in the range of 1%- 5% in water kept at room temperature of about 25 °C.

In accordance with an aspect, the obtained modified starch composition has a solubility index in the range of 17%- 35% in boiling water (at 100°C).

In accordance with an aspect, the obtained modified starch composition has a solubility index in the range of 1%- 5% in chloroform.

In accordance with an aspect, the thermogravimetric analysis of the obtained modified starch composition shows a characteristic peak at a temperature between 120- 180°C. In accordance with an embodiment, the characteristic peak is obtained at the temperature of about 150 °C. In accordance with an embodiment, the obtained modified starch composition has a moisture content in the range of 0.4- 0.9%. In some embodiments, the modified starch composition has a moisture content of 0.6-0.7 %.

In accordance with an embodiment, the blend comprising starch and the compatibilizing agent is prepared at room temperature of about 25-35 °C. In accordance with an embodiment, the blend comprising starch and the compatibilizing agent is prepared without the addition of water. In accordance with an embodiment, the processing of the blend comprising starch and the compatibilizing agent in the twin-screw processor is carried out without the addition of water. In accordance with an embodiment, said blend is prepared in any known mixer. In some embodiments, said blend is prepared in a ribbon mixer.

In accordance with an embodiment, the blend comprises starch and the compatibilizing agent in a w/w ratio of 2: 1-4: 1. In some embodiments, the w/w ratio of starch and the compatibilizing agent is in the range of 2: 1-3.5: 1. In an exemplary embodiment, the w/w ratio of starch and the compatibilizing agent is 3.3:1 to 3.4:1, and in particular 3.34:1. Figure 1 shows a comparative study of the solubility of the modified starch composition, when the w/w ratio of starch and compatibilizing agent (glycerol) is 3.34:1. The solubility studies were performed in cold water at a temperature of 10°C, water at room temperature, water a temperature of 80°C and 90°C, boiling water, and in chloroform.

Any known source of starch may be used. In accordance with an embodiment, the starch is a natural starch and is selected from the group consisting of potato, wheat, com, cassava, rice, peas starch and a combination thereof. In accordance with an embodiment, the starch is a chemically or physically modified starch, selected from the group consisting of oxidised, carboxymethylated, hydroxyalkylated, enzymatically treated starch, and combinations thereof. In some embodiments, a blend of natural as well as chemically or physically modified starch is used. In accordance with an embodiment, the compatibilizing agent is selected from the group consisting of glycerol, glycerin, sorbitol and a combination thereof. In some embodiments, the compatibilizing agent is glycerol.

In a further embodiment, the modified starch composition comprises additives such as fillers, emulsifiers, fragrance, essential oils, fatty acids. Any known fillers may be used. In accordance with an embodiment, the fillers are selected from the group consisting of calcium carbonate, calcium oxides, coco peat, and combinations thereof. Any known emulsifier may be used. In accordance with an embodiment, the emulsifier is selected from the group consisting of tween 20, glycerol monostearate, alcohol ester and combinations thereof.

The blend comprising starch and the compatibilizing agent is processed through the twin-screw processor at the temperature ranging between 60-110°C. In some embodiments, the blend is processed at the temperature ranging between 60-100°C.

In accordance with an embodiment, the blend comprising starch and the compatibilizing agent is fed to the twin-screw processor at a feeding rate of 30-100 Kg/ hr. In accordance with an embodiment, the twin-screw processor is operated at a screw speed of 80-140 rpm. In some embodiments, the twin-screw processor is operated at a screw speed of 80-120 rpm. In accordance with an embodiment, the twin-screw processor has a length/ diameter (L/D) in the range of 60/40. In accordance with an embodiment, the residence time ranges between 1-4 minutes.

In accordance with an embodiment, the twin-screw processor for preparing the modified starch composition is a co-rotating twin-screw processor. In accordance with an embodiment, the co-rotating twin-screw processor is a co-rotating twin-screw extruder. In accordance with an exemplary embodiment, the twin-screw extruder is Omega 40H or Omega 60H (Steer Engineering Pvt. Ltd.). In accordance with an embodiment, the modified starch composition is extruded in the form of a pellet. In an alternative embodiment, the modified starch composition is cast in the form of a film.

The modified starch composition could be combined with any known biodegradable polymer such as polybutylene adipate terephthalates (PBATs), polycaprolactones (PCLs), polybutylene succinate adipates (PBSs), polylactic acids (PLAs) to form a biodegradable polymer composition.

In order that this disclosure may be better understood, the following examples are set forth. These examples are for the purpose of illustration only and the exact compositions, methods of preparation and embodiments shown are not limiting of the disclosure.

Also described herein are method for characterizing the modified starch compositions in accordance with one or more embodiments of the present disclosure.

Examples:

Example 1: Process for preparation of the exemplary modified starch composition (starch: glycerol- 3.34:1)

3.34 parts starch and 1 part glycerol were mixed without the addition of water at room temperature in a ribbon mixer. The blend comprising starch and the compatibilizing agent was fed and conveyed through a co-rotating twin-screw extruder (Omega 40H (Steer Engineering Pvt. Ltd.)) and the modified starch composition was obtained from the discharge zone of the extruder. The machine specifications and processing conditions are stated in Tables 1 and 2, below.

Table 1: Machine specifications and processing conditions

Table 2: Screw Configuration* * List of Abbreviations for Elements

The obtained composition was cast in the form of a film and solubility studies were performed on the obtained film as well as a conventional cast film comprising 30% w/w of glycerol, prepared in accordance with Farahnaky et al. Effect of Glycerol on Physical And Mechanical Properties Of Wheat Starch Edible Films. Journal of Texture Studies 44 (2013) 176-186. Figure 2 shows a comparative study of the solubility of the modified starch obtained in accordance with an embodiment of present disclosure vis-a-vis said conventional cast film.

Observation: It was observed that while the modified starch composition in accordance with the present disclosure (MSC1) resulted in a material that was hydrophobic and did not solubilize in water, the conventional film dissolved in water at 80°C and any increase in temperature. Particularly, the conventional film showed solubility of 30% at 80°C. Thus, contrary to the conventional film, the disclosed film of modified starch composition resisted and retained its nature and was not soluble in water. This could be explained on account of the saturated hydrogen bonding in the disclosed modified starch composition.

Example 2: Thermogravimetric Analysis of the exemplary modified starch composition

The process of Example 1 was repeated to obtain pellets of modified starch composition. The thermogravimetric analysis (TGA) of the pellets of the modified starch composition was then performed. The thermogravimetric analysis was conducted in a thermogravimetric analyser (Perkin Elmer TGA 4000) under a nitrogen atmosphere at a heating rate of 10°C per minute. The change in weight as a function of temperature was recorded. Figure 3 shows the thermogravimetric analysis of the obtained modified starch composition. A characteristic peak was observed at a temperature of 150°C. Example 3: Mechanical properties of a blend of the modified starch composition and a biodegradable polymer-PBAT.

Preparation of biodegradable polymer composition: The ingredients used to form the exemplary biodegradable polymer composition (BPCI) are listed in Table 3, below.

Table 3: Ingredients for preparing exemplary biodegradable polymer composition.

The biodegradable polymer composition was prepared by first preparing a blend comprising starch and a compatibilizing agent at room temperature in a ribbon mixer. The blend comprising starch and the compatibilizing agent was fed and conveyed through a co-rotating twin-screw extruder to obtain the modified starch composition. PBAT was fed to the twin-screw extruder through a side feeder. The modified starch and PBAT was conveyed through the twin-screw extruder and the biodegradable polymer composition- BPC1 was obtained from the discharge zone of the co-rotating twin-screw extruder.

The mechanical properties of this biodegradable polymer composition were compared with that of PBAT/thermoplastic starch blends disclosed in Can et al. (PBAT/thermoplastic starch blends: “Effects of oxidized starch and compatibilizer content”; AIP Conference Proceedings 1914, 070004 (2017)). Table 4 shows a comparison of the mechanical properties of biodegradable polymer composition with said prior art polymer composition.

Table 4: Comparison of mechanical properties

Observation: It was observed that the biodegradable polymer composition comprising the disclosed modified starch exhibits significant improvement in mechanical properties when compared with prior known blends of PBAT and starch at same w/w ratio.

INDUSTRIAL APPLICABILITY

The process of the present disclosure is simple and cost-effective. The modified starch composition so obtained is highly stable, insoluble in water, exhibits minimal or zero hydrophilic properties, while demonstrating a high degree of biodegradability. The modified starch composition finds applications as a food-grade biodegradable packaging material. Thus, the modified starch composition provides an alternative to fossil-fuel based plastic in food and non-food applications.

The process conditions disclosed herein, including temperature, speed of operation as well as ratio of starch and the compatibilizing agent provide mechanical and thermal interaction such that a modified starch is obtained which is substantially insoluble in cold water, water at room temperature as well as chloroform.

The obtained modified starch composition is susceptible to both aerobic and anaerobic decomposition.

The modified starch composition obtained from the process of the present disclosure may be combined with a biodegradable polymer such as polybutylene adipate terephthalates (PBATs), polycaprolactones (PCLs), polybutylene succinate adipates (PBSs), polylactic acids (PLAs), Polyhydroxy buyterate co valerate (PHBV) to obtain food-grade biodegradable packaging materials. Applications of such materials include but are not limited to straws, storage bottles for preserves and drinking bottles, and grocery bags for instance. The obtained modified starch composition enables preparing biodegradable polymer compositions comprising higher proportions of starch (greater than 50%) while exhibiting significant improvement in mechanical properties. Thus, the disclosed process reduces cost of preparing biodegradable polymer compositions.