Box–Behnken experimental design for optimization of chitosan foam materials reinforced with cellulose and zeolite

Foam materials produced from biopolymers stand out as a more environmentally friendly insulation material solution. This study presents a comprehensive investigation into the development and optimization of chitosan‐based foam materials using a Box–Behnken design. The foams were engineered using varying proportions of chitosan (0.5–3%), cellulose (0.5–3%), and zeolite (0.5–3%), targeting their application as thermal insulators. The physical and thermal properties of the foams that were produced were affected by the type and ratios of components, with density and thermal conductivity ranging from 0.0853 to 0.1915 g cm−3 and 0.0324 to 0.0921 W mK−1, respectively. Higher chitosan content improved insulation properties and mechanical strength whereas zeolite increments increased density and thermal conductivity. Using statistical analysis through the Box–Behnken design, we optimized the foam formulations, achieving minimum thermal conductivity and maximum compression strength at an averaged density, suggesting a strong potential for environmental sustainability applications. The recommended optimal chitosan:cellulose:zeolite composition ratio of 3:3:0.88 provides a valuable insight for tailored foam material formulation. This study shows the relationships between the composition of a composite material and its resultant properties, optimizing its preparation for industrial applicability in an environmentally conscious way within the context of insulation and construction. This investigation contributes to the field of material science by highlighting the versatility and potential of biopolymers but also aligns with the increasing need for green building materials.