Scalable production of hydrophobic starch/beeswax films by continuous solution casting

Abstract Starch is an appealing natural polymer for the scaled‐up production of biodegradable plastics. However, the low water resistance of starch has made its broad applicability largely doubted. In this study, starch was combined with beeswax (BW) through a pilot scale continuous solution casting (CSC) technique to reduce water affinity while keeping the ensuing films totally biodegradable. The phase morphology, surface wettability, and water vapor permeability (WVP) of films were examined over a broad BW–starch mass ratio (0.3–0.7). Emulsified, surfactant‐free starch/BW films were successfully obtained at a productivity of 0.55 m 2 film h −1 . The water contact angle increased nearly by 100% at 30 wt% BW, leading to remarkable reductions in WVP. BW droplets well distributed within the starch matrix played a key role in enhancing the water barrier properties of films. CSC of starch/BW films offers a basis to design new hydrophobic formulations for applications that require biodegradable plastics with high moisture resistance.