Effect of starch type and screw speed on mechanical properties of extrusion-cooked starch-based foams

Potato starch and corn starch are popular basic raw materials in the processing of biopolymers. One of the processing methods employed in the manufacture of biopolymers is extrusion-cooking technique. With specific parameters and equipment configurations, it is possible to obtain a wide variety of starch-based biopolymers. Loose fill foams are usually produced with the use of polystyrene, but the adverse environmental effects of conventional plastics provide an incentive for the development of new, environmentally friendly raw materials. The aim of the study was to apply the extrusion-cooking technique to prepare starch-based foams from potato starch and corn starch under various extruder screw speeds applied during processing. Process efficiency and energy consumption were also tested during processing. The expanded foams were analysed by means of cutting and compression tests to evaluate selected mechanical properties. The type of starch used and the processing screw speed had an impact on the efficiency and specific energy requirements of the process. The results showed that the screw speed had a significant effect on the cutting forces in the tested foams as well as on its compression properties. Higher hardness of foams was observed when potato starch was used as the basic raw material. Moreover, corn starch foams proved to be more elastic in compression tests.