Introduction

The guiding force behind the development of biodegradable polymers is, among others, the disadvantages of conventional plastics associated with excessive exploitation of non-renewable fossil resources, limited recycling, their landfilling, and environmental pollution. Furthermore, problems with the disposal of plastics from petroleum-derived raw materials as waste mean that more and more emphasis is placed on the environmental aspect in EU regulations [1].

Our research work is aimed at reducing the disadvantages of biodegradable polymers, e.g., by developing compositions that can be processed using conventional methods to reduce the costs of the machine park, searching for alternative production methods, or improving their useful properties. There are many possibilities for obtaining non-standard compositions from various biodegradable polymers for specific applications by reducing costs using cheaper organic or mineral fillers. The blend of polymers such as poly (lactic acid) and polyhydroxyalkanoates with other natural additives such as starch or cellulose allows for obtaining materials similar to or superior to conventional polymers, maintaining their useful properties and biodegradability properties. On the other hand, optimal amounts of filler make it possible to develop a low-cost material with acceptable handling and processing properties [1,2,3].

Polymer matrix composites account for a significant share of the production of composite materials worldwide. Using a polymer matrix enabled them to obtain desirable properties as construction materials, such as low mass, ease of shaping, corrosion resistance, vibration damping, and thermal and electrical insulation. These composites are used as unloaded elements, e.g., machine casings, construction of electrical devices, light but heavily loaded structures, e.g., aircraft or racing cars, and in construction and sports equipment. The reinforcing phase in polymer matrix composites can be fibers or powder fillers. Fibers in composites are mainly used to increase the modulus of elasticity and mechanical strength of the material and reduce the coefficient of thermal expansion. The most popular are glass, carbon, aramid, polyethylene, boron, and natural fibers, e.g., jute, kenaf, or linen [4,5,6,7,8,9].

It looks that adding natural filler to biodegradable polymers is the best way to reinforce them because it is affordable and produces the desired results. Many studies have been conducted on natural reinforced polymer composites, both synthetic and biodegradable. Cellulose, hemicellulose, pectin, and lignin are the most often used natural fibers. The composites reinforced with lignocellulosic fibers have a high density/young’s modulus ratio, are biodegradable, and are extremely stiff. They are also readily available and significantly less expensive than synthetic fibers. These days, lignocellulose fiber-reinforced composites are used to make a lot of different things, like window frames, furniture, car dashboards, train sleepers, etc. [10, 11].

The use of natural reinforcement in polymer composites is becoming more and more popular. This is mainly related to the renewable source of their origin and the ability to biodegrade in the environment. The advantages also include low density, availability, and low price. However, natural reinforcement also has disadvantages that limit their use. These include common mechanical properties compared to synthetic fibers, poor wettability, and adhesion of the polymer matrix, low thermal resistance, flammability, and susceptibility to bacteria and fungi. Another limitation is the selection of the composite matrix material for natural reinforcement, the processing temperature of which cannot be higher than the degradation temperature of the natural fillers used, i.e., approximately 200–250 °C [12,13,14,15]. In the context of current challenges related to growing problems with waste management, finding alternative solutions for the most problematic materials is necessary. The biodegradable polymers combine a much shorter degradation time with the advantages of polymeric materials, thanks to the development of new connections, including natural reinforcement, thanks to which the whole thing still has a biodegradable character while reducing the total costs of materials, and improvement of the processing process [16,17,18,19].

The aim of the research was to indicate the critical share of the filler in the matrix and to investigate the influence of the volume content of natural filler in the form of walnuts and chicken eggshells on the differential scanning calorimetry (DSC) analysis and processing properties (MFR) of the developed composite materials for the pure biodegradable polymer BIOPLAST. ®GS 2189.

Materials and experimental procedure

Materials

BIOPLAST® GS 2189 was purchased from German company BIOTEC GmbH & Co KG Company. The manufacturer provides that it is a poly (lactic acid)-based biopolymer, completely biodegradable in an industrial composting environment. It contains 75% of renewable raw material. This thermoplastic material is suitable for injection molding, thermoforming, 3D printing, and blown film extrusion according to the producer, with a melt flow rate (MFR) 29 g 10 min−1 in 190 °C, 2.16 kg. The properties of the selected polymer material are presented in Table 1 [20, 21].

Table 1 Properties of the polymer material—Bioplastic GS 1289 [20]

As fillers for the composite materials, collected waste walnuts and hen’s eggshells were used. Walnut and hen’s eggshells were cleaned of fatty membranes. Cleaning was done manually. In the first phase, the obtained waste was washed in warm water. (Large impurities were separated, including some large fragments of membranes.) Then, the shells were dried in a laboratory dryer of POL-EKO (drying time 24 h), and the remaining impurities were manually removed. The cleaned shells were subjected to another drying cycle (drying time 48 h), and then, the raw material prepared in this way was placed in the planetary mill of PULVERISETTE, filled with twenty zirconium oxide balls. The grinding process lasted 10 min at 400 rpm. The ground fillers were passed through a sieve with a fraction of 0.5 µm. The components prepared in this way were sent to the homogenization process.

Preparation of composite materials

Work on developing a fully biodegradable material was divided into several primary stages (Fig. 1). In the first one, the focus was on the selection of appropriate constituent components of composite materials and the determination of reasonable (from the application point of view) proportions between the matrix and the filler. In the next step, variants of the composite material were produced—a series of technological tests were performed. Finally, standardized samples were made, and the strength properties of the proposed solutions were determined—the influence of the type and quantity of the filler on these properties was determined.

Fig. 1
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Diagram of stages of the developing process

The selected polymer material, BIPOLAST® GS 2189 as a matrix, was dried at 90 °C for 24 h to remove absorbed water before the next processing step. Thereafter, the preparing fillers were homogenized with the BIOPLAST GS 2189 on the crusher at the appropriate percentages and masses presented in Table 2.

Table 2 The percentage composition of the matrix and the filler in developed composite materials—adopted symbols

The homogenization process was carried out at the temperature of 180 °C and consisted of two five-minute stages on the ZAMAK MERCATOR VM-30 crusher. In the first stage, the rotation speed of the blades was 10 rpm, and in the second stage, it was increased to 20 rpm. The obtained material was crushed into smaller particles to facilitate insertion into the cylinder of the laboratory piston injection molding machine of ZAMAK MERCATOR, in the next stage, for the preparation of standardized samples and prototypes. Samples manufacturing parameters for standardized samples during injection molding are presented in Table 3.

Table 3 The sample manufacturing parameters during injection molding

Differential scanning calorimetry (DSC)

Differential scanning calorimetry (DSC) analysis of the composite materials and raw materials was performed using a DSC 3 scanning calorimeter from Mettler-Toledo, operating in the temperature range from − 90 to 700 °C. Samples for the DSC measurements were sealed in 40 µl standard aluminum crucibles with a single hole punched in the lid. The total mass of the sample was between 9 and 10 mg. Each sample was heated in the temperature range from − 20 to 180 °C. In the beginning, the samples were kept at − 20 °C for 10 min, after which the temperature was increased to 180 °C at a heating rate of 10 K min−1. The measurement for each sample was repeated twice at time intervals: immediately after the first heating run and cooling the sample to 25 °C, and after 1 day, leaving the sample in a desiccator for 24 h at room temperature.

Mass melt flow rate (MFR)

The melt flow index has become a widely recognized criterion in the appraisal of the processing of thermoplastic materials. The MFR of the tested polymer materials and composites was determined using the Mflow BMF-001 load plastometer from Zwick/Roell following the PN-EN ISO 1133 standard “Plastics. Determination of mass melt flow rate (MFR) and volumetric melt flow rate (MVR) of thermoplastics.” In the case of the materials considered, a test temperature of 160 °C was used each time. A batch of material weighing 5 g was placed in the testing channel and preheated for 300 s. In most cases, a load of 2.16 kg was applied to the heated mass; in four cases, a load of 5 kg was used. After the test piston reached the measurement range, the actual measurement of material flow was started, the measuring distance was 30 s, and the set number of sections was 10. After the test, each section was weighed using a RADWAG AS 220.R2 analytical laboratory scale with an accuracy of 0.1 mg, and data were entered into the Test XpertII program to determine the mass melt flow rate of the tested polymer materials. The collected data made it possible to determine the MFR of the tested materials.

Scanning electron microscopy (SEM)

SEM images for particles of BIOPLAST were taken. The model of microscope used was a Zeiss Supra 35 scanning electron microscope equipped with the DEMINI optical column. Sample preparation involved sputter coating the specimen with a conductive AuPd (80/20) material using a Bal-Tec SCD 050 device with the following parameters: spraying time: 90 s; current intensity: 40 mA; voltage (resulting): 52 V; detectors: SE2, and QBSD. In the study, the EDS (energy-dispersive X-ray spectroscopy) system was used, which is used for observing, analyzing, and characterizing surface, surface layer, and elemental composition.

Results and discussion

Biodegradable thermoplastic composites were prepared from a thermoplastic matrix with the trade name—BIOPLAST® GS 1289 and natural fillers in the form of ground after waste walnut shells or hen’s eggshells in different mass percents: 10, 20, 30, 50, 60, or 70 mass/%. The real chemical composition of BIOPLAST® GS 2189 is unknown since the industrial polymer supplier does not give it. The sole information provided in the datasheet is that the BIOPLAST® GS 2189 contains 75% renewable raw material and has a biobased carbon share of 69% [21]. SEM microscopy was used to realize the images on raw material samples (Fig. 2). During observation of SEM-micrograph of the BIOPLAST® GS 2189, the presence of particles up to nanometric size up to 10 µm was revealed. These particles have multi-walled geometry and are evenly distributed throughout the entire volume of material. To identify them, EDS point analysis was performed (Fig. 3), which showed a high percentage of calcium in the matrix material. This may indicate a calcium carbonate content in the matrix. According to the work of other research groups, the BIOPLAST® GS 2189 is a blend that contains around 60 mass% of poly(lactic acid) (PLA), 20 mass% of calcium carbonate and 20 mass% potato starch. The share of the last component is confirmed by the producer [20]. PLA has excellent mechanical properties, including a high degree of transparency, a high Young’s modulus, and tensile strength. It is also very easily processed. However, PLA is frequently modified due to its expensive cost and a few disadvantages, such as brittleness and low flexibility. These properties can be improved by using, like by the manufacturer, thermoplastic starch (TPS) that exerts an influence on the segmental mobility of PLA like plasticizer of the mixture and calcium carbonate as a nucleating agent [22,23,24].

Fig. 2
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The raw BIOPLAST GS 2189: a granules; b SEM-micrograph of the structure

Fig. 3
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EDS analysis of the raw BIPLAST GS 2189. The atomic % of C, O, and Ca was done on the table and an SEM picture of the tested area

The purpose of our research work was to determine the critical concentration of biodegradable fillers that will further improve the processing properties of Bioplast and at the same time reduce the cost of the obtained materials. We used DSC and MFR analysis to make a preliminary determination of the quality of the obtaining new materials. The knowledge of heat transfer and rheology is essential for the selection of appropriate processing parameters for composite materials. The heat flow measured by DSC provides detailed information on the phase transition range. The thermal properties of composites BIOPLAST® GS 2189 with waste walnut shells or hen’s eggshell powder were studied by DSC analysis. A good approach for DSC analysis of samples, such as polymers and materials made of them, is to heat the sample twice under the same measurement conditions after a defined cooling cycle. The first heating run provides information about the thermal history of the sample: production, storage, and sample preparation [25].

In Fig. 4, a summary of curves of sample B_E_90/10 after three heating runs is presented, where the third run is made after the seasoning of the sample at room temperature for 24 h. In all curves of samples: neat BIOPLAST® GS 2189 and its composites, the following transformations were recorded: glass transition temperature (Tg), exothermic effect—associated with cold crystallization temperature (Tcc), and endothermic effect—associated with melting temperature (Tm). This indicates the semicrystalline morphology of the samples. According to the literature, semicrystalline polylactide shows better mechanical properties compared to amorphous [23]. In the curve of the first heating run, we observed an enthalpy relaxation peak immediately after the glass transition (Fig. 4, black line). This effect is the result of physical aging that occurs in an amorphous polymer held below its Tg. The presence of the overlapped peak is difficult to determine precisely the position of the Tg. After the first heating run of the sample, this history is deleted. The value of the glass transition temperature was determined from the third heating run, because only here was this signal sufficiently clear to determine it (Table 4, Figs. 5 and 6), whereas the first heating run allows determining the degree of crystallinity of the resulting composites during the manufacturing process. Each additional heating and cooling cycle leads to rearrangement, and recrystallization of the composite after the melting of crystals in the first heating run. In the second and third heating runs, often the heat of cold crystallization is almost as the heat of melting and when calculating the value of the degree of crystallization, it is often close to zero. As is well known, the crystallization process of polymers is slow due to the lower mobility of the polymer chain segments and requires appropriate time [26].

Fig. 4
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DSC curves biodegradable plastic composite material based on BIOPLAST and hen’s eggshells powder B_E_90/10: the first heating run (black line), the second heating run (blue line), and the third heating run (red line)

Table 4 Thermal analysis data for BIOPLAST GS 1289 and their composite materials after the first and third heating runs
Fig. 5
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DSC curves BIOPLAST GS 1289 (blue line) and biodegradable plastic composite materials based on BIOPLAST and hen’s eggshells powder: B_E_90/10 (red line), B_E_80/20 (purple line), B_E_70/30 (brown line), B_E_50/50 (green line), B_E_40/60 (black line)

Fig. 6
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DSC curves BIOPLAST GS 1289 (blue line) and biodegradable composite materials based on BIOPLAST and walnut shell powder: B_N_90/10 (black line), B_N_80/20 (red line), B_N_70/30 (green line), B_N_50/50 (purple line), B_N_40/60 (brown line), B_N_30/70 (cyan line)

The degree of crystallinity is determined based on the following equation:

$$X\text{c }=\frac{({H}_{\text{m }}- {H}_{\text{cc}})}{{H}_{\text{m}}^{o}}$$
(1)

where XC—the degree of crystallinity, %. Hm—the heat of melting, J g−1. Hcc—the heat of cold crystallization, J g−1, and \({H}_{\text{m}}^{\text{o}}\)—heat of melting for PLA 100% crystalline = 93 J g−1 [22].

The values of Tg, Xc, Tcc, Hcc, Tm1 and Tm2, and Hm are given in Table 4.

The results of a comparison of third heating run DSC curves of BIOPLAST® GS 2189 and its composites with hen’s eggshell powder as filler are shown in Fig. 5 or its composites with walnut shell powder as filler in Fig. 6. All curves of BIOPLAST and its biocomposites (Figs. 4, 5 and 6) exhibit an exothermic peak at temperatures ranging from 102 to 115 °C, corresponding to TCC. This is the effect reorganization of amorphous into crystalline forms on account of the increased macromolecular flexibility and mobility upon increasing temperature [27]. Then, we can observe on the curves the overlapped two endothermic peaks which are melting temperatures (Tm1 and Tm2). This effect is attributed to the phenomenon of lamellar rearrangement and polymorphism of PLA crystalline structure. According to the literature, two endothermic peaks around 150 °C appear related to the melting of the α′ and α-crystalline forms. The peak at the lower temperature is related to the melting of the α′-form and its recrystallization into the α-form, while the second peak corresponds to the melting of the α-form. The domains of the α′ and α-forms coexist in the crystallite [28, 29]. PLA shows the various types of crystal forms: (α, β, and γ) depending on the crystallization conditions, which is related to the technique of its forming (processing) or obtaining its composites. The most common orthorhombic α-form occurs in conventional melt and solution crystallization conditions. The less ordered α′-crystals form via melt- or cold crystallization below 120 °C. Industrial processing, such as injection molding, frequently involves quickly cooling the melt, which, at best, allows α′-crystal formation at high supercooling of the melt and suppresses slow crystallization at high temperatures. In general, the chain conformation and crystal system of the α′-form are similar to that of α, but with looser and less ordered chain packing. This conformation of α′-crystals leads to a lower modulus and barrier properties and higher elongation at break compared to α-crystal [23, 30].

A step in the baseline of the DSC measurement curve is defined as the glass transition (Tg), while the amorphous regions change from a brittle glassy state to a flexible state as they are heated. In Table 3, it can be observed that Tg of raw BIOPLAST GS 1289 is lowered by adding up to 30 mass % of hen’s eggshell powder, while that of walnut shell meal is lowered up to 70 mass %. The lowest value of Tg, around 50.5 °C, was recorded for compositions B_N_70/30 and B_N_80/20 (Table 4), while for pure PLA it is about 60 °C [23]. For these samples, the highest values of crystallinity degree for the type of filler used were also obtained, 19% and 15.8%, respectively. For these samples, after extrusion and seasoning before DSC testing, no exothermic peak from cold crystallization was recorded and the Tm signal was a clear single peak, which indicates that order α-crystal has been formed [23, 29]. It should be noted that composition B_N_80/20 also had the highest average MFR value of 27.12 g 10 min−1 at 160 °C with a load of 2.16 kg, whereas raw BIOPLAST has a value of 10.27 g 10 min−1 at 160 °C with a load of 2.16 kg. It can be observed correlation between the glass transition temperature, the degree of crystallinity, and the average MFR value. A correlation was observed that the higher the degree of crystallinity of the sample and the lower the glass transition temperature, the higher the MFR value was and thus the given composition exhibited the best processing properties. The lower the degree of crystallinity, the higher the ratio of amorphous PLA, which exhibits the adherent feature to the screw during injection molding [28]. The slow crystallization process of PLA can be effectively accelerated by using plasticizers to increase chain mobility and heterogeneous nucleators to increase nucleation density [31].

The difference and the problem of introducing more than 30 mass % of hen’s shell powder may be due to the calcium carbonate already present in BIOPLAST. In the literature, it is possible to find papers describing studies of PLA biocomposites with walnut shells or with lignin as fillers [32, 33]. In contrast, no research paper was found where BIOPLAST materials with walnut shells were prepared. The chemical structure of walnut shells consists mainly of cellulose (23.9%), hemicellulose (22.4%), lignin (50.3%), and ash (3.4%) [34]. Lignin has a highly branched structure with hydroxyl groups that can form hydrogen bonds with PLA’s carboxylic groups and the aromatic rings in lignin can interact with the carbonyl groups in PLA, increasing interfacial adhesion (compatibility) between these two materials [35]. It has been shown that lignin improved the thermal stability and photochemical degradation of PLA as well as its mechanical properties [36, 37]. This would explain the results we obtained: the maximum amount of filler that could be mixed with BIOPLAST to make desirable composite and the MFR values. Furthermore, lignin is used as a sustainable photothermal block for composites [38].

The values of the second peak of melting temperature are the minimum temperature that could be used in processing these composites. However, the safest processing temperature to use is the one corresponding to the endset melting temperature, which was 160 °C for these biocomposites (Fig. 7).

Fig. 7
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The effect of the amount of natural fillers in the biocomposite materials on glass transition (Tg): BIOPLAST and walnut shells (B_N—blue line); BIOPLAST and hen’s eggshells (B_E—orange line)

The results of the mass flow rate (MFR) tests and the statistical parameters for the tested materials are presented in Table 5. The processing properties of the produced composite materials were analyzed based on the mass flow rate index values. In this way, it is possible to assess the fluidity of the material at the processing temperature for a given load. The obtained results of the MFR test confirm that the share of the fillers used in the polymer increases the rheological sensitivity to the processing temperature. This is manifested by an increase in the value of the MFR index compared to the pure matrix. Performing the test at a temperature of 160 °C made testing all composite variants possible. However, in the case of 30, 50, and 60 mass % eggshells powder, the piston load was increased from 2.16 to 5 kg. The lower load did not allow downloading the correct episodes. The melt flow rate is related to the change in the viscosity of the material. An increase in the melt flow index value indicates a decrease in the polymer viscosity value. The additives used positively affected the processing properties. (They reduced the viscosity of the material.) Only in the case of using the highest share of filler (over 30 mass %) was the opposite phenomenon observed, i.e., deterioration of processing properties.

Table 5 Determined mass flow rates MFR as a function of filler percentage for walnut shells and eggshells

As a result of the study, it was found that the use of natural fillers has a positive effect on increasing the processing properties of the developed composites. Reducing the amount of polymer used benefits ecology—less polymer material is introduced, and the biodegradation process is accelerated. The main reason for using these natural fillers is the product’s low price and easy availability on the market. Neat BIOPLAST® GS 2189 shows Tg at approximately 52 °C. Meanwhile, the addition of filler in the form of flour from waste walnut shells powder lowers this temperature. The lowest value of Tg, 50.5 °C was recorded for compositions of 30% waste walnut shells powder and 70% BIOPLAST (B_N_70/30) and 20% waste walnut shells powder and 80% BIOPLAST (B_N_80/20). Composition B_N_80/20 also had the highest mass flow rate index (MFR) (at 160 °C with a load of 2.16 kg) of 27.12 g 10 min−1 at 160 °C, where BIOPLAST has a value of 10.27 g 10 min−1. Weaker composites were obtained by the addition of hen’s eggshells powder, especially when its content exceeded 50 mass %. Tg values for B_E_50/50 and B_N_40/60 were 52.6 °C and 54.9 °C, respectively. This was reflected in the MFR, which was 9.87 g 10 min−1 at 160 °C for a load of 5 kg. Similarly, relationships were observed for the values of Tcc and Tm on the formulation of the composite as for Tg. The results obtained confirm that the proportion of fillers used in the polymer increases the rheological sensitivity to processing temperature.

The initial increase in the mass flow rate coefficient is related to introducing a more significant amount of heterogeneous nucleators into the system in the form of natural fillers [28]. In the case of walnut shell powder, this effect is intensified by its chemical composition and the lignin present in it, which acts as a plasticizer—increases chain mobility—making the material easier to process. Thanks to these factors, the possibility of introducing fillers into PLA increases, which is reflected in the presented results. Composites with walnut shell powder are characterized by an increase in melt flow rate by up to 30 mass %, while those with hen eggshells powder increase by up to 20 mass %. After reaching these filler shared values, there is a sharp decrease in melt flow rate, including processing capacity. This is most likely due to the “oversaturation” of the system with the filler—reaching a critical concentration of the filler in the plastic. The matrix ceases to fulfil its functions and becomes only the binder of the component [39]. It was also observed that the best melt flow rate when using walnut shell powder persists at 30 mass % share. Meanwhile, the melt flow rate for eggshell powder is the highest in the 20 mass % share, after which it drops dramatically. It is impossible to produce a composite (without manufacturing problems) with over 50 mass % filler content.

Conclusions

Research has shown that it is possible to successfully replace synthetic filler, with waste reducing the cost of material. Fully biodegradable polymer composites with a large share natural fillers (walnut shell and eggshells powder) have been made using a friendly environment PLA matrix. All tested composites are made from by products, which are inexpensive and widely available. Their usefulness and attractiveness are further expanded by the fact that they are entirely biodegradable and feature a matrix that degrades quickly. Biodegradable thermoplastic composites were prepared from a thermoplastic matrix with the trade name—BIOPLAST GS 1289 and natural fillers in the form of ground after waste walnut shells and hen eggshells powder in different mass percents: 10, 20, 30, 50, 60, or 70 mass %. The real chemical composition of BIOPLAST® GS 2189 is unknown since the industrial polymer supplier does not give it. The sole information provided in the datasheet is that the BIOPLAST® GS 2189 contains 75% renewable raw material and has a biobased carbon share of 69%. According to the research presented by Atli, Candelier, Alteyrac [38], the BIOPLAST® GS 2189 contains around 60% of poly (lactic acid) (PLA), 20% of starch, and 20% of CaCO3. Incorporating natural fillers into the matrix above made it possible to determine their maximum concentration while maintaining acceptable processing properties.

The described studies indicate the maximum proportion of filler in the BIOPLAST® GS 2189 matrix in the case of walnut shell powder is 30 mass %, while in the case of hen eggshell powder, it is 20 mass %. This is valuable information from the point of view of technological properties—targeted work on calibrating process parameters for composites with a high content of natural fillers.

It has been established that walnut shell powder is a better filler due to the own chemical composition of lignin, a natural plasticizer. This factor allows more filler to be introduced into the matrix while maintaining good processing and functional properties.

Against the background of the research, walnut shells powder is a promising filler, which, when combined with the matrix, is much more processable and has satisfactory characteristics. In addition, it has advantages related to the process of future degradation of the developed material solutions. The advantages of this filler are also confirmed in the literature [6, 13, 17, 40], where research on combining this with other polymer matrices is described. The obtained MFR and Tg results allowed to establish the manufacturing parameters of standardized test samples were selected and calibrated based on the information obtained completed during the research works. Packages of standardized samples were produced, consisting of disks (hardness test), paddles (static tensile test), and beams (three-point bending and impact test) for each developed composition. Samples have been referred for further testing to enable the development of complete material characterization needed to future market implementation.