Advancing sustainable agriculture: a novel multi-layer film approach to plastic mulching

Harshal J. Kansara; Yvan D. Hernandez-Charpak; Elizabeth M. Buck; Jarmila Haseler; Thomas A. Trabold; Jeffrey S. Lodge; Christopher L. Lewis; Carlos A. Diaz

doi:10.1038/s44264-025-00106-9

Advancing sustainable agriculture: a novel multi-layer film approach to plastic mulching

Harshal J. Kansara
, Yvan D. Hernandez-Charpak
, Elizabeth M. Buck
, Jarmila Haseler
, Thomas A. Trabold
, Jeffrey S. Lodge
, Christopher L. Lewis
, Carlos A. Diaz

Research output: Contribution to journal › Article › peer-review

1 Scopus citations

Abstract

Biodegradable plastic mulch films (BMFs) have been used in agriculture as an alternative to conventional polyethylene mulches, offering benefits such as reduced labor costs and in-soil biodegradability. However, BMFs often degrade slowly, and fragments remain in the soil for multiple years. This study introduces a novel multi-layer agricultural mulch film (MLAMF) with poly(butylene adipate-co-terephthalate) (PBAT) outer layers and a thermoplastic starch (TPS) core, designed to enhance biodegradation and reduce plastic accumulation. In laboratory composting (LC), the MLAMF achieved 64% mass loss over 365 days, while pure PBAT films degraded by only 12%. In industrial composting (IC) conditions, the MLAMF and PBAT films showed 58% and 33% mass loss in 14 days, respectively. Respirometry tests indicate that the presence of TPS accelerates mineralization relative to the monolayer film. A small scale field trial revealed no statistically significant differences in onion yield or rot incidence between MLAMF and the commercial films.

Original language	English
Article number	64
Journal	npj Sustainable Agriculture
Volume	3
Issue number	1
DOIs	https://doi.org/10.1038/s44264-025-00106-9
State	Published - Dec 2025
Externally published	Yes

Funding

The authors extend their gratitude to Robert Putney and Elias Putney of Impact Earth Rochester for providing the opportunity to test the films at their industrial composting site. Special thanks to Sivani Kancharla for her assistance in supporting the biodegradation trials. Cornell Cooperative Extension (CCE) was instrumental in facilitating this study, with particular recognition to the CCE Monroe County team—Andrea Lista, Marci Muller, and Michael Grady Kincaid. Additional thanks to the CCE Cornell Vegetable Program team—Robert Hadad, Nina Gropp, Lori Koenick, and Julie Kikkert, as well as Cornell University’s Lake Erie Research and Education Laboratory farm technicians, including Ted Taft and Dan Sprague. A portion of this work was presented at the 39th Polymers Processing Society Conference, Cartagena, Colombia, May 19–23, 2024. This research was supported by the Foundation for Food and Agriculture Research (FFAR) under grant #CA19-SS-0000000013 and by New York Empire State Development through award #C190155. The views, results, findings, and interpretations presented in this manuscript are those of the Rochester Institute of Technology and do not necessarily reflect the views or policies of New York State.

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10.1038/s44264-025-00106-9

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title = "Advancing sustainable agriculture: a novel multi-layer film approach to plastic mulching",

abstract = "Biodegradable plastic mulch films (BMFs) have been used in agriculture as an alternative to conventional polyethylene mulches, offering benefits such as reduced labor costs and in-soil biodegradability. However, BMFs often degrade slowly, and fragments remain in the soil for multiple years. This study introduces a novel multi-layer agricultural mulch film (MLAMF) with poly(butylene adipate-co-terephthalate) (PBAT) outer layers and a thermoplastic starch (TPS) core, designed to enhance biodegradation and reduce plastic accumulation. In laboratory composting (LC), the MLAMF achieved 64\% mass loss over 365 days, while pure PBAT films degraded by only 12\%. In industrial composting (IC) conditions, the MLAMF and PBAT films showed 58\% and 33\% mass loss in 14 days, respectively. Respirometry tests indicate that the presence of TPS accelerates mineralization relative to the monolayer film. A small scale field trial revealed no statistically significant differences in onion yield or rot incidence between MLAMF and the commercial films.",

author = "Kansara, \{Harshal J.\} and Hernandez-Charpak, \{Yvan D.\} and Buck, \{Elizabeth M.\} and Jarmila Haseler and Trabold, \{Thomas A.\} and Lodge, \{Jeffrey S.\} and Lewis, \{Christopher L.\} and Diaz, \{Carlos A.\}",

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AU - Haseler, Jarmila

AU - Trabold, Thomas A.

AU - Lodge, Jeffrey S.

AU - Lewis, Christopher L.

AU - Diaz, Carlos A.

PY - 2025/12

Y1 - 2025/12

N2 - Biodegradable plastic mulch films (BMFs) have been used in agriculture as an alternative to conventional polyethylene mulches, offering benefits such as reduced labor costs and in-soil biodegradability. However, BMFs often degrade slowly, and fragments remain in the soil for multiple years. This study introduces a novel multi-layer agricultural mulch film (MLAMF) with poly(butylene adipate-co-terephthalate) (PBAT) outer layers and a thermoplastic starch (TPS) core, designed to enhance biodegradation and reduce plastic accumulation. In laboratory composting (LC), the MLAMF achieved 64% mass loss over 365 days, while pure PBAT films degraded by only 12%. In industrial composting (IC) conditions, the MLAMF and PBAT films showed 58% and 33% mass loss in 14 days, respectively. Respirometry tests indicate that the presence of TPS accelerates mineralization relative to the monolayer film. A small scale field trial revealed no statistically significant differences in onion yield or rot incidence between MLAMF and the commercial films.

AB - Biodegradable plastic mulch films (BMFs) have been used in agriculture as an alternative to conventional polyethylene mulches, offering benefits such as reduced labor costs and in-soil biodegradability. However, BMFs often degrade slowly, and fragments remain in the soil for multiple years. This study introduces a novel multi-layer agricultural mulch film (MLAMF) with poly(butylene adipate-co-terephthalate) (PBAT) outer layers and a thermoplastic starch (TPS) core, designed to enhance biodegradation and reduce plastic accumulation. In laboratory composting (LC), the MLAMF achieved 64% mass loss over 365 days, while pure PBAT films degraded by only 12%. In industrial composting (IC) conditions, the MLAMF and PBAT films showed 58% and 33% mass loss in 14 days, respectively. Respirometry tests indicate that the presence of TPS accelerates mineralization relative to the monolayer film. A small scale field trial revealed no statistically significant differences in onion yield or rot incidence between MLAMF and the commercial films.

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Advancing sustainable agriculture: a novel multi-layer film approach to plastic mulching

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