Tailoring Cellulose Derivative Gel Matrices for Bacillus subtilis Delivery: Effects of Polymer Molecular Weight on Stability and Biocontrol

Cellulose-derived gel films are promising matrices for the immobilization and delivery of beneficial microorganisms in sustainable plant protection. This study evaluated the effects of polymer molecular weight and chemical structure on the physicochemical properties and biocontrol performance of hydroxyethyl cellulose (HEC) films of low, medium, and high molecular weight, as well as sodium carboxymethyl cellulose (CMC-Na), loaded with Bacillus subtilis. The films were characterized in terms of morphology, swelling behavior, mechanical properties, microbial viability, and antifungal activity against Fusarium avenaceum and Alternaria solani. Increasing HEC molecular weight produced progressively denser and more homogeneous gel networks, resulting in improved structural integrity, whereas CMC-Na formed dense but less stable networks. Swelling studies at pH 4, 7, and 9 showed high water uptake for all HEC systems, with enhanced structural stability observed in high-molecular-weight films, whereas CMC-Na dissolved rapidly under all conditions. Mechanical testing further confirmed that increasing molecular weight enhanced stiffness and tensile strength but reduced flexibility. Immobilized in gel matrices, B. subtilis remained viable after 12 months of storage and rapidly reactivated after rehydration. All biohybrid films inhibited fungal growth, with stronger formulation-dependent responses against F. avenaceum than against A. solani. In general, polymer molecular weight and structure were identified as key parameters controlling network organization, hydration behavior, mechanical performance, and biological functionality. These findings highlight the potential of cellulose-derived gel matrices as tunable carriers for microbial biocontrol applications.