Antibacterial performance of ZnO-based fillers with mesoscale structured morphology in model medical PVC composites

•ZnO-based nanostructured microparticles were prepared by microwave synthesis.•Prepared ZnO imparts excellent antibacterial activity to PVC composites.•The microparticulate character of filler makes it processable as common powders.•The inevitable disadvantages of nanoparticles are circumvented.•General rule of proneness of microparticles for antibacterial composites

Three different ZnO-based antibacterial fillers having different morphologies in microscale region were prepared by the use of the microwave assisted synthesis protocol created in our laboratory with additional annealing in one case. Further, PVC composites containing 0.5–5 wt.% of ZnO based antibacterial fillers were prepared by melt mixing and characterized by scanning electron microscopy (SEM) and X-ray diffractometry (XRD). Mechanical testing showed no adverse effect on the working of polymer composites due to either of the fillers used or the applied processing conditions in comparison with the neat medical grade PVC. The surface antibacterial activity of the compounded PVC composites was assessed against Escherichia coli ATCC 8739 and Staphylococcus aureus ATCC 6538P according to ISO 22196: 2007 (E). All materials at almost all filler loading levels were efficient against both species of bacteria. The material with the most expanding morphology assuring the largest contact between filler and matrix achieved an excellent level of more than 99.9999% reduction of viable cells of E. coli in comparison to untreated PVC and performed very well against S. aureus, too. A correlation between the morphology and efficacy of the filler was observed and, as a result, a general rule was formulated which links the proneness of the microparticles to perform well against bacteria to their shape and morphology.