The production of biodegradable gluten-based protein foams showing complete natural degradation in soil after 26 days is reported, as an alternative to commercial foams in disposable sanitary articles that rely on non-biodegradable materials. The foams were developed from an extensive evaluation of different foaming methodologies (oven expansion, compression moulding, and extrusion), resulting in low-density foams (ca. 400 kg/m3) with homogenous pore size distributions. The products showed the ability to absorb 3–4 times their weight, reaching ranges for their use as absorbents in single-use disposable sanitary articles. An additional innovative contribution is that these gluten foams were made from natural and non-toxic wheat protein, glycerol, sodium and ammonium bicarbonate, making them useful as fossil-plastic-free replacements for commercial products without the risk of having micro-plastic and chemical pollution. The impact of different processing conditions on forming the porous biopolymer network is explained, i.e., temperature, pressure, and extensive shear forces, which were also investigated for different pH/chemical conditions. The development of micro-plastic-free foams mitigating environmental pollution and waste while using industrial co-products is fundamental for developing large-scale production of single-use items. A sanitary pad prototype is demonstrated as an eco-friendly material alternative that paves the way for sustainable practices in manufacturing, and contributes to the global effort in combating plastic pollution and waste management challenges, Sustainable Development Goals: 12, 13, 14, and 15.

Glycerol-plasticized wheat gluten was explored for producing soft high-density biofoams using dry upscalable extrusion (avoiding purposely added water). The largest pore size was obtained when using the food grade ammonium bicarbonate (ABC) as blowing agent, also resulting in the highest saline liquid uptake. Foams were, however, also obtained without adding a blowing agent, possibly due to a rapid moisture uptake by the dried protein powder when fed to the extruder. ABC's low decomposition temperature enabled extrusion of the material at a temperature as low as 70 °C, well below the protein aggregation temperature. Sodium bicarbonate (SBC), the most common food-grade blowing agent, did not yield the same high foam qualities. SBC's alkalinity, and the need to use a higher processing temperature (120 °C), resulted in high protein cross-linking and aggregation. The results show the potential of an energy-efficient and industrially upscalable low-temperature foam extrusion process for competitive production of sustainable biofoams using inexpensive and readily available protein obtained from industrial biomass (wheat gluten). 

To broaden the range in structures and properties, and therefore the applicability of sustainable foams based on wheat gluten expanded with ammonium-bicarbonate, we show here how three naturally ocurring multifunctional additives affect their properties. Citric acid yields foams with the lowest density (porosity of ~50%) with mainly closed cells. Gallic acid acts as a radical scavenger, yielding the least crosslinked/ aggregated foam. The use of a low amount of this acid yields foams with the highest uptake of the body-fluid model substance (saline, ~130% after 24 hours). However, foams with genipin show a large and rapid capillary uptake (50% in one second), due to their high content of open cells. The most dense and stiff foam is obtained with one weight percent genipin, which is also the most crosslinked. Overall, the foams show a high energy loss-rate under cyclic compression (84-92% at 50% strain), indicating promising cushioning behaviour. They also show a low compression set, indicating promising sealability. Overall, the work here provides a step towards using protein biofoams as a sustainable alternative to fossil-based plastic/rubber foams in applications where absorbent and/or mechanical properties play a key role.