Effects of Starch Sources and Supplementary Materials on Starch Based Foam Trays

Firstly, foam trays were produced from glyoxal cross-linked wheat, potato and corn starches and their mixtures. The most suitable starch type for starch-based foam tray production was selected according to the level of water absorption, density, surface and cross-section micrographs of the foam trays. It was decided that a wheat and potato starch blend was the most suitable starch source for producing the foam trays because they have the lowest water absorption percentage (25.5 ± 0.7%), low density (0.17 ± 0.01 g/cm³) and a smooth surface. Potato–wheat starch foam trays with fibres were produced by adding wheat and wood fibres. Unlike wood fibres addition, wheat fibres significantly decreased the percentage of water absorption (16.63 ± 1.2%) and density (0.115 ± 0.013 g/cm³) of the tray. Also, the trays including wheat fibre had a lighter colour than the wheat–potato starch tray. To further reduce water absorption of the tray, the trays were made by adding two different types of lipids (beeswax or shortening and three different types of filler materials—kaolin, montmorillonite or zinc oxide nanoparticles). According to the level of water absorption of the trays, it was decided that shortening and zinc oxide nanoparticles, in addition to kaolin, were respectively the most suitable lipid and filler materials. The foam trays were produced by adding these supplementary materials. The addition of shortening slightly, zinc oxide nanoparticles moderately and kaolin greatly increased the density of the wheat potato starch tray including fibre. However, the percent of water absorption of the trays containing wheat fibre + shortening or wheat fibre + shortening + zinc oxide nanoparticles decreased 6.4 ± 0.01 and 5.9 ± 0.3%, respectively.