Surfactant-free starch-graphene composite films as simultaneous oxygen and water vapour barriers

Abstract A single coating formulation for multifunctional composites, such as a gas barrier against both oxygen and water vapour, is the holy grail for the packaging industry. Since the last decade, graphene has been touted as the ideal barrier material in composites due to its morphology and impermeability to all gases. However, this prospect is limited by either poor dispersion of graphene or excess surfactants to aid the dispersion, both leading to shortcuts that allow gas permeation through the composite. Here, we demonstrate a combined gas barrier with starch-graphene composite films made from a single formulation of surfactant-free starch nanoparticle-stabilized graphene dispersion (2.97 mg mL⁻¹). Hence, the incorporated graphene reduces the permeability of both the oxygen and the water vapour by over 70% under all the relative humidity conditions tested. Moreover, these films are foldable and electrically conductive (9.5 S m⁻¹). Our surfactant-free approach of incorporating graphene into an industrially important biopolymer is highly relevant to the packaging industry, thus offering cost-effective and water-based solution depositions of multifunctional composite films for wide-ranging applications, such as gas barriers in food packaging.