A multidisciplinary team of European scientists has developed a novel fully biobased and biodegradable material composite designed for cosmetic packaging, with mechanical and thermal performance comparable to traditional plastics like polyethylene (PE) and polypropylene (PP).
Published in Scientific Reports (Nature Portfolio, July 2025), the research introduces a multi-component material that blends poly(3-hydroxybutyrate-co-3-hydroxyvalerate) (PHBV), polylactic acid (PLA), chitosan (CS), acetyl tributyl citrate (ATBC), phycocyanin, and essential plant oils. According to the authors, it marks the first time such a composite has been successfully developed for commercial cosmetic packaging applications.
“This work presents the first green material composite comprising PHBV, PLA, CS, essential oil, ATBC, and phycocyanin specifically designed for cosmetic packaging as a sustainable alternative to fossil-based plastics,” the authors write.
The development responds directly to rising industry pressure to reduce dependency on fossil-based polymers. Global plastic production reached 374 million tonnes in 2023, with packaging accounting for 36% of output. Despite widespread efforts, recycling rates remain low—just 14% for packaging plastics globally—fueling demand for truly biodegradable alternatives that don’t sacrifice performance.
The newly formulated composite shows promising results. In mechanical testing, the material achieved tensile strength and Young’s modulus values within the range typically observed in PP and PE. The incorporation of ATBC, a biodegradable plasticizer, increased the ductility and processability of the polymer matrix, though it caused a slight reduction in strength.
CS, derived from chitin in seafood waste, enhanced stiffness (Young’s modulus) while maintaining biodegradability. Meanwhile, the addition of phycocyanin, a natural pigment from spirulina, and essential oils helped imbue the material with natural color and aroma—valuable features for the cosmetics sector.
From a thermal standpoint, the composite demonstrated stability suitable for high-temperature processing, with degradation temperatures ranging from 255°C to 308°C. Differential scanning calorimetry (DSC) confirmed that ATBC reduced the glass transition temperature of the blend, improving molecular mobility—an effect beneficial to injection molding and extrusion.
Morphological analysis via scanning electron microscopy and X-ray scattering revealed good structural integration between the phases, although some weak interfacial bonding and minor nanovoids were observed. Despite this, all formulations were successfully injection molded into standard specimens, and the most complex blend was also trialed using additive manufacturing.
Notably, the 3D printing trial was conducted using FGF (Fused Granular Fabrication) technology on a Piocreat G5 printer. The researchers achieved successful extrusion at 205°C, although pigment degradation during printing remains a challenge. “The printing process for the developed material still needs optimization,” the team admitted, citing cohesion issues between pellets due to ATBC during feeding.
Hydrophobicity tests showed that all formulations were hydrophilic (contact angles < 90°), which the authors note may actually favor hydrolytic degradation—a positive feature for end-of-life disposal. Color measurements confirmed visible darkening due to thermal degradation of pigments during both molding and 3D printing.
While the work remains in the pre-commercial stage, it underlines a significant stride toward market-ready biopolymers capable of replacing PE and PP in premium, rigid cosmetic packaging formats.
“These materials have an attractive natural colour and smell, with possible applications in cosmetic industry packaging… and could be produced from additive manufacturing technologies,” the paper concludes.
