Development of Biodegradable High‐Alumina Clay‐Modified Poly (Butylene Adipate‐Co‐Terephthalate) Composites for Sustainable Packaging Applications

ABSTRACT The urgent need for sustainable alternatives to conventional packaging has driven extensive research into biodegradable materials that reduce pollution and support the circular economy. Here, we present a novel approach to enhancing the properties of poly(butylene adipate‐co‐terephthalate) by incorporating high‐alumina content clay in varying amounts of 0.25–2 weight percentages (wt%) using an ex‐situ fabrication method. This innovative composite design addresses the limitations of traditional PBAT by significantly improving its mechanical, thermal, and barrier properties, making it a viable candidate for high‐performance sustainable packaging. FT‐IR, XRD, and FE‐SEM confirmed a well‐dispersed clay network within the PBAT matrix. Quantitatively, the addition of alumina clay enhanced the elastic modulus to 31.9 MPa, representing a marked increase in stiffness. The composites also demonstrated improved thermal stability up to 364.3°C. Surface hydrophobicity was significantly increased (92.1°), while water vapor permeability reduced to 3.76 × 10 −12 g·cm·cm −2 s −1 mmHg −1 , showcasing superior moisture resistance compared to neat PBAT. Developed films showed excellent resistivity in various chemical environments for up to 45 days and remarkable packaging efficiency for up to 14 days. These findings highlight the unique potential of high‐alumina clay‐reinforced PBAT composites as robust, environmentally friendly materials that meet the diverse demands of the packaging industry.