This study aims to optimize the biocomposites of sago pith waste (SPW) for sustainable packaging applications. The biocomposite was prepared using the biodegradable polymer polybutylene adipate-co-terephthalate (PBAT) as a matrix and methylendifenyl diisocyanate (MDI) as a chain extender. RSM-CCD was used to assess the impact of the incorporation of SPW (5-20% p/p) and MDI (1–5%) into the PBAT matrix on the tensile strength and elongation of biocomposites by melt mixing. The optimal formula shown by RSM was 5% SPW and 5% MDI, which resulted in a 5.14 MPa tensile strength and 8.14% elongation. The barrier properties of all treatments, including moisture content, contact angle, and water absorption, were checked. The optimal formula showed good barrier properties compared to other treatments: water content of 3.12%, contact angle of 42.84°, and water absorption of 0.82%. Other characterizations of SEM, FTIR, DSC, TGA, and biodegradability tests showed an increase in SPW-PBAT compatibility due to the use of MDI. MDI as a chain extender had a positive impact on the material's strength, and the addition of SPW accelerated the degradation process, thus improving biodegradability. Keywords: Biocomposite, Chain extender, Melt-mixing, Response Surface Methodology, Sago pith waste.
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