Characterization and Antimicrobial Activity of PLA-Laminated PBAT/TPS Films Incorporated with Silver Nanocomposites

Multilayer packaging—engineered by integrating complementary materials such as plastics, paper, and aluminum—has become a cornerstone technology for enhancing shelf life, minimizing spoilage, and reinforcing the mechanical integrity of packaging formats including films, pouches, and bottles. In this study, a laminate was developed by thermally bonding polylactic acid (PLA) with a poly(butylene adipate-co-terephthalate) (PBAT)/thermoplastic starch (TPS) matrix embedded with silver nanoparticles (Ag-NPs) at 0–3 wt.%. The resulting structures were systematically evaluated for their barrier performance, physicochemical characteristics, and antimicrobial functionality. Fourier-transform infrared (FTIR) spectroscopy confirmed the absence of chemical interactions between Ag-NPs and the polymer matrix, indicating physical dispersion rather than chemical bonding. However, at higher loading (3 wt.%), scanning electron microscopy with energy-dispersive X-ray spectroscopy (SEM-EDX) revealed notable nanoparticle aggregation. Functionally, the multilayer films demonstrated markedly improved water vapor barrier properties compared to single-layer PBAT/TPS films. Migration studies showed that silver release increased with nanoparticle concentration and was significantly enhanced under acidic conditions relative to distilled water. Importantly, Ag-NP-incorporated laminates exhibited pronounced antibacterial activity against Staphylococcus aureus. Collectively, these findings highlight the potential of Ag-NP-enriched, starch-based multilayer laminates as next-generation active packaging systems that combine with effective microbial control.