Novel LDPE/Chitosan Rosemary and Melissa Extract Nanostructured Active Packaging Films

Effect of catalyst carrier type and concentration on oxygen-scavenging property and characteristics of iron-based active films

The presence of oxygen can degrade food quality, making it essential to remove oxygen from the packaging headspace of food products. In this study, the effect of catalyst type and concentration on iron-based oxygen-scavenging films was investigated to enhance the oxygen removal efficiency in food packaging films. Among the investigated catalysts, calcium chloride and lipophilic silica improved the oxygen-scavenging capacity more than sodium chloride and hydrophilic silica. As the catalyst content was increased from 0.1 to 6.0 %(w/w), the oxygen content (%) in the package decreased from 3.90 to 0.36%. Application of oxygen-scavenging films in apple packaging decreased the apple browning index from 52.87 to 38.13 and reduced the oxygen concentration inside the package from 9.8 to 0.0%. Therefore, the food packaging film developed in this study can be used as a food packaging material that removes oxygen and thus prevents food quality deterioration.

Supplementary Information

The online version contains supplementary material available at 10.1007/s10068-024-01520-4.

Shelf Life of Minced Pork in Vacuum-Adsorbed Carvacrol@Natural Zeolite Nanohybrids and Poly-Lactic Acid/Triethyl Citrate/Carvacrol@Natural Zeolite Self-Healable Active Packaging Films

Enhancing food preservation and safety using environmentally friendly techniques is urgently needed. The aim of this study was to develop food packaging films using biodegradable poly-L-lactic acid (PLA) as biopolymer and carvacrol (CV) essential oil as an antioxidant/antibacterial agent for the replacement of chemical additives. CV was adsorbed onto natural zeolite (NZ) via a new vacuum adsorption method. The novel nanohybrid CV@NZ with a high CV content contained 61.7%wt. CV. Pure NZ and the CV@NZ nanohybrid were successfully dispersed in a PLA/triethyl citrate (TEC) matrix via a melt extrusion process to obtain PLA/TEC/xCV@NZ and PLA/TEC/xNZ nanocomposite films with 5, 10, and 15%wt CV@NZ or pure NZ content. The optimum resulting film PLA/TEC/10CV@NZ contained 10%wt. CV@NZ and exhibited self-healable properties, 22% higher tensile strength, 40% higher elongation at break, 45% higher water barrier, and 40% higher oxygen barrier than the pure PLA/TEC matrix. This film also had a high CV release content, high CV control release rate as well as 2.15 mg/L half maximal effective concentration (EC50) and 0.27 mm and 0.16 mm inhibition zones against Staphylococcus aureus and Salmonella enterica ssp. enterica serovar Typhimurium, respectively. This film not only succeeded in extending the shelf life of fresh minced pork, as shown by the total viable count measurements in four days but also prevented the lipid oxidation of fresh minced pork and provided higher nutritional values of the minced meat, as revealed by the heme iron content determination. It also had much better and acceptable sensory characteristics than the commercial packaging paper.

Low-Density Polyethylene-Based Novel Active Packaging Film for Food Shelf-Life Extension via Thyme-Oil Control Release from SBA-15 Nanocarrier

The use of natural raw substances for food preservation could provide a great contribution to food waste reduction, circular economy enhancement, and green process application widening. Recent studies indicated that the use of porous materials as adsorbents for natural essential oils provided nanohybrids with excellent antioxidant and antimicrobial properties. Following this trend in this work, a thymol oil (TEO) rich SBA-15 nanohybrid was prepared and characterized physiochemically with various techniques. This TEO@SBA-15 nanohybrid, along with the pure SBA-15, was extruded with low-density polyethylene (LDPE) to develop novel active packaging films. Results indicated that TEO loading was higher than other porous materials reported recently, and the addition of both pure SBA-15 and TEO@SBA-15 to the LDPE increased the water/oxygen barrier. The film with the higher thyme-oil@SBA-15 nanohybrid content exhibited a slower release kinetic. The antioxidant activity of the final films ignited after 48 h, was in the range of 60-70%, and was almost constant for 7 days. Finally, all tests indicated a sufficient improvement by the addition of thyme-oil@SBA-15 nanohybrids in the pure LDPE matrix and the concentration of wt. 10% of such nanocarriers provided the optimum final LDPE/10TEO@SBE-15 active packaging film. This material could be a potential future product for active packaging applications.

Characterization and modeling of diffusion kinetics of rosemary oleoresin extract from gellan gum-based film

Fresh food products are highly prone to oxidation and microbial attack, rendering them unsuitable for consumption. Thus, active food packaging was developed to protect and prolong food shelf-life. Zein/gellan gum (GG) based active film is developed by incorporating rosemary oleoresin extract (ROE) (0-20%). The films were characterized by their barrier and antioxidant properties. The release behavior of ROE in fatty and hydrophilic food stimulants was investigated via mathematical modeling. The active films incorporated with 20% ROE have significantly higher oxygen barrier and oxygen transfer is reduced by 20% compared to the control. A tortuous path is created with ROE, which impedes oxygen movement across the film. ROE addition improved water resistance performance by reducing the active film swelling ratio by 31%. This improvement is attributed to the hydrophobic nature of ROE. FTIR shows that the interaction between ROE and the active film is primarily hydrogen bonding and electrostatic interactions. Active film exhibits excellent antioxidant activity, with high TPC, DPPH scavenging activity, and FRAP. Mathematical modeling revealed a higher diffusivity (D) of ROE in fatty food stimulants at 24 °C, attributed to high polarity and solubility in fatty food stimulants. Overall, this active film has an excellent antioxidant effect and could potentially be used as food packaging for high-fat food products to prevent oxidation.

Graphical abstract

Thymol@Natural Zeolite Nanohybrids for Chitosan/Polyvinyl-Alcohol-Based Hydrogels Applied as Active Pads

Currently, food saving, a circular economy, and zero environmental fingerprints are of major interest. Scientific efforts for enhanced food preservation using "green" methods have been intensified. Even though chemicals could achieve such targets effectively, the global trend against the "greenhouse effect" suggests the use of environmentally friendly biobased materials for this purpose. In this study, the promising biopolymer chitosan is incorporated with the promising biodegradable polymer polyvinyl alcohol to produce an improved biopolymeric matrix. This biodegradable biopolymer was further mixed homogeneously with 15% thymol/nano-zeolite nanohybrid material. The properties of the final developed film were improved compared to the relevant values of chitosan/polyvinyl alcohol film. The mechanical properties were enhanced significantly, i.e., there was a 34% increase in Young's modulus and a 4.5% increase in the ultimate tensile strength, while the antioxidant activity increased by 53.4%. The antibacterial activity increased by 134% for Escherichia coli, 87.5% for Staphylococcus aureus, 32% for Listeria monocytogenes, and 9% for Salmonella enterica. The water vapor diffusion coefficient and the oxygen permeability coefficient decreased to -51% and -74%, respectively, and thus, the water vapor and oxygen barrier increased significantly. The active pads were used in strawberries, and the antimicrobial activity evaluation against the mold of fungi was carried out. The visual evaluation shows that the active pads could extend the shelf life duration of strawberries.

Thymol@activated Carbon Nanohybrid for Low-Density Polyethylene-Based Active Packaging Films for Pork Fillets' Shelf-Life Extension

Τhe replacement of food packaging additives and preservatives with bio-based antioxidant/antibacterial compounds has been a common practice in recent years following the trend of bioeconomy and nanotechnology. Such bio-additives are often enclosed in nanocarriers for a controlled release process. Following this trend in this work, a thymol (TO)-rich activated carbon (AC) nanohybrid was prepared and characterized physicochemically with various techniques. This TO@AC nanohybrid, along with the pure activated carbon, was extruded with low-density polyethylene (LDPE) to develop novel active packaging films. The codenames used in this paper were LDPE/xTO@AC and LDPE/xAC for the nanohybrid and the pure activated carbon, respectively. X-ray diffractometry, Fourier-transform infrared spectroscopy, and scanning electron microscopy measurements showed high dispersity of both the TO@AC nanohybrid and the pure AC in the LDPE matrix, resulting in enhanced mechanical properties. The active film with 15 wt.% of the TO@AC nanohybrid (LDPE/15TO@AC) exhibited a 230% higher water/vapor barrier and 1928% lower oxygen permeability than the pure LDPE film. For this active film, the highest antioxidant activity referred to the DPPH assay (44.4%), the lowest thymol release rate (k₂ ≈ 1.5 s^-1), and the highest antibacterial activity were recorded, resulting in a 2-day extension of fresh pork fillets' shelf-life.

Developing Post-Consumer Recycled Flexible Polypropylene and Fumed Silica-Based Nanocomposites with Improved Processability and Thermal Stability

Collection and mechanical recycling of post-consumer flexible polypropylene packaging is limited, principally due to polypropylene being very light-weight. Moreover, service life and thermal-mechanical reprocessing degrade PP and change its thermal and rheological properties according to the structure and provenance of recycled PP. This work determined the effect of incorporating two fumed nanosilica (NS) types on processability improvement of post-consumer recycled flexible polypropylene (PCPP) through ATR-FTIR, TGA, DSC, MFI and rheological analysis. Presence of trace polyethylene in the collected PCPP increased the thermal stability of the PP and was significantly maximized by NS addition. The onset decomposition temperature raised around 15 °C when 4 and 2 wt% of a non-treated and organically modified NS were used, respectively. NS acted as a nucleating agent and increased the crystallinity of the polymer, but the crystallization and melting temperatures were not affected. The processability of the nanocomposites was improved, observed as an increase in viscosity, storage and loss moduli with respect to the control PCPP, which were deteriorated due to chain scission during recycling. The highest recovery in viscosity and reduction in MFI were found for the hydrophilic NS due to a greater impact of hydrogen bond interactions between the silanol groups of this NS and the oxidized groups of the PCPP.

Development and Evaluation of a Novel-Thymol@Natural-Zeolite/Low-Density-Polyethylene Active Packaging Film: Applications for Pork Fillets Preservation

Sustainability, the circular economy, and the "greenhouse" effect have led the food packaging industry to use naturally available bio-compounds. The integration of such compounds in packaging films increases food safety and extends food shelf-life. The development of an active/antioxidant packaging film based on the widely commercially used low-density polyethylene, natural zeolite, and Thymol, a natural extract from thyme oil, is presented in this work. The obtained active films were characterized using X-Ray Diffraction, Fourier-Transform Infrared Spectroscopy, Scanning Electron Microscopy, and Differential Scanning Calorimetry techniques. The tensile strength, water-oxygen barrier properties, and total antioxidant activity were measured. Low-density polyethylene incorporated with Thymol@Natural Zeolite at a proportion of 15 wt% was the most promising material and was used as film to wrap-up pork fillets. The thiobarbituric acid (TBA) method and heme iron measurements indicated a delayed lipids oxidation using this film. A linear correlation between the TBA method and heme iron values seems to be established, which could result in a fast method to determine the degree of lipid oxidation in pork fillets. Finally, a two-stage diffusion process during Thymol release was observed, and the values of the diffusion coefficient was 2.09 × 10^-7 and 1.21 × 10^-8 cm²/s for each stage. The applied pseudo-second sorption model provided a rate constant k₂ = 0.01647 (s^-1). These results indicate the strong potential of such films to be used as food packaging materials free of E-number preservatives.

Chitosan Based Materials in Cosmetic Applications: A Review

This review provides a report on the properties and recent advances in the application of chitosan and chitosan-based materials in cosmetics. Chitosan is a polysaccharide that can be obtained from chitin via the deacetylation process. Chitin most commonly is extracted from cell walls in fungi and the exoskeletons of arthropods, such as crustaceans and insects. Chitosan has attracted significant academic interest, as well as the attention of the cosmetic industry, due to its interesting properties, which include being a natural humectant and moisturizer for the skin and a rheology modifier. This review paper covers the structure of chitosan, the sources of chitosan used in the cosmetic industry, and the role played by this polysaccharide in cosmetics. Future aspects regarding applications of chitosan-based materials in cosmetics are also mentioned.

Development, Characterization, and Evaluation as Food Active Packaging of Low-Density-Polyethylene-Based Films Incorporated with Rich in Thymol Halloysite Nanohybrid for Fresh "Scaloppini" Type Pork Meat Fillets Preservation

A new era is rising in food packaging and preservation, with a consequent focus on transition to "greener" and environmentally friendly techniques. The environmental problems that are emerging nowadays impose use of natural materials for food packaging applications, replacement of chemical preservatives with natural organic extractions, such as essential oils, and targeting of new achievements, such as further extension of food shelf-life. According to this new philosophy, most of the used materials for food packaging should be recyclable, natural or bio-based, and/or edible. The aim of this work was to investigate use and efficiency of a novel food packaging developed based on commercial LDPE polymer incorporated with natural material halloysite impregnated with natural extract of thyme oil. Moreover, a direct correlation between the stiff TBARS method and the easiest heme iron measurements method was scanned to test food lesions easier and faster. The result of this study was development of the LDPE/10TO@HNT film, which contains the optimum amount of a hybrid nanostructure and is capable to be used as an efficient active food packaging film. Furthermore, a linear correlation seems to connect the TBARS and heme iron measurements.

Nanocomposite Film Development Based on Chitosan/Polyvinyl Alcohol Using ZnO@montmorillonite and ZnO@Halloysite Hybrid Nanostructures for Active Food Packaging Applications

The global turn from the linear to the circular economy imposes changes in common activities such as food packaging. The use of biodegradable materials such as polyvinyl alcohol, natural raw materials such as clays, and food byproducts such as chitosan to develop novel food packaging films attracts the interest of industrial and institutional research centers. In this study, novel hybrid nanostructures were synthesized via the growth of zinc oxide nanorods on the surface of two nanoclays. The obtained nanostructures were incorporated with chitosan/polyvinyl alcohol composite either as nanoreinforcement or as an active agent to develop packaging films. The developed films were characterized via XRD, FTIR, mechanical, water-vapor diffusion, water sorption, and oxygen permeability measurements. Antimicrobial activity measurements were carried out against four different pathogen microorganisms. XRD indicated the formation of an intercalated nanocomposite structure for both types of nanoclays. Furthermore, improved tensile, water/oxygen barrier, and antimicrobial properties were recorded for all films compared to the pure chitosan/polyvinyl alcohol film. Overall, the results indicated that the use of the bio-based developed films led to an extension of food shelf life and could be used as novel active food packaging materials. Among them, the most promising film was the 6% wt. ZnO@halloysite.

Innovative Approach for Controlling Black Rot of Persimmon Fruits by Means of Nanobiotechnology from Nanochitosan and Rosmarinic Acid-Mediated Selenium Nanoparticles

The protection of persimmon fruits (Diospyros kaki L.) from postharvest fungal infestation with Alternaria alternata (A. alternate; black rot) is a major agricultural and economic demand worldwide. Edible coatings (ECs) based on biopolymers and phytocompounds were proposed to maintain fruit quality, especially with nanomaterials' applications. Chitosan nanoparticles (NCt), rosmarinic acid bio-mediated selenium nanoparticles (RA/SeNPs) and their composites were produced, characterized and evaluated as ECs for managing persimmon black rot. The constructed NCt, RA/SeNPs and NCt/RA/SeNPs composite had diminished particles' size diameters. The ECs solution of 1% NCt and NCt/RA/SeNPs composite led to a significant reduction of A. alternata radial growth in vitro, with 77.4 and 97.2%, respectively. The most powerful ECs formula contained 10 mg/mL from NCt/RA/SeNPs composite, which significantly reduced fungal growth than imazalil fungicide. The coating of persimmon with nanoparticles-based ECs resulted in a significant reduction of black rot disease severity and incidence in artificially infected fruits; the treatment with 1% of NCt/RA/SeNPs could completely (100%) hinder disease incidence and severity in coated fruits, whereas imazalil reduced them by 88.6 and 73.4%, respectively. The firmness of fruits is greatly augmented after ECs treatments, particularly with formulated coatings with 1% NCt/RA/SeNPs composite, which maintain fruits firmness by 85.7%. The produced ECs in the current study, based on NCt/RA/SeNPs composite, are greatly recommended as innovatively constructed human-friendly matrix to suppress the postharvest destructive fungi (A. alternata) and maintain the shelf-life and quality of persimmon fruits.

Design of Polymeric Films for Antioxidant Active Food Packaging

Antioxidant active food packaging can extend the shelf life of foods by retarding the rate of oxidation reactions of food components. Although significant advances in the design and development of polymeric packaging films loaded with antioxidants have been achieved over the last several decades, few of these films have successfully been translated from the laboratory to commercial applications. This article presents a snapshot of the latest advances in the design and applications of polymeric films for antioxidant active food packaging. It is hoped that this article will offer insights into the optimisation of the performance of polymeric films for food packaging purposes and will facilitate the translation of those polymeric films from the laboratory to commercial applications in the food industry.

Effect of Copper and Titanium-Exchanged Montmorillonite Nanostructures on the Packaging Performance of Chitosan/Poly-Vinyl-Alcohol-Based Active Packaging Nanocomposite Films

In this study, CuMt and TiMt montmorillonites were produced via an ion-exchange process with Cu⁺ and Ti⁴⁺ ions. These nanostructured materials were characterized with X-ray diffraction (XRD) and fourier transform infrared spectroscopy (FTIR) measurements and added as nanoreinforcements and active agents in chitosan (CS)/poly-vinyl-alcohol (PVOH)-based packaging films. The developed films were characterized by XRD and FTIR measurements. The antimicrobial, tensile, and oxygen/water-barrier measurements for the evaluation of the packaging performance were carried out to the obtained CS/PVOH/CuMt and CS/PVOH/TiMt films. The results of this study indicated that CS/PVOH/CuMt film is a stronger intercalated nanocomposite structure compared to the CS/PVOH/TiMt film. This fact reflected higher tensile strength and water/oxygen-barrier properties. The antibacterial activity of these films was tested against four food pathogenic bacteria: Escherichia coli, Staphylococcus aureus, Salmonella enterica and Listeria monocytogenes. Results showed that in most cases, the antibacterial activity was generated by the CuMt and TiMt nanostructures. Thus, both CS/PVOH/CuMt and CS/PVOH/TiMt films are nanocomposite candidates with very good perspectives for future applications on food edible active packaging.

Synthesis of a Novel Chitosan/Basil Oil Blend and Development of Novel Low Density Poly Ethylene/Chitosan/Basil Oil Active Packaging Films Following a Melt-Extrusion Process for Enhancing Chicken Breast Fillets Shelf-Life

An innovative process for the adsorption of the hydrophobic Basil-Oil (BO) into the hydrophilic food byproduct chitosan (CS) and the development of an advanced low-density polyethylene/chitosan/basil-oil (LDPE/CS_BO) active packaging film was investigated in this work. The idea of this study was the use of the BO as both a bioactive agent and a compatibilizer. The CS was modified to a CS_BO hydrophobic blend via a green evaporation/adsorption process. This blend was incorporated directly in the LDPE to produce films with advanced properties. All the obtained composite films exhibited improved packaging properties. The film with 10% CS_BO content exhibited the best packaging properties, i.e., 33.0% higher tensile stress, 31.0% higher water barrier, 54.3% higher oxygen barrier, and 12.3% higher antioxidant activity values compared to the corresponding values of the LDPE films. The lipid oxidation values of chicken breast fillets which were packaged under vacuum using this film were measured after seven and after fourteen days of storage. These values were found to be lower by around 41% and 45%, respectively, compared with the corresponding lipid oxidation values of pure LDPE film.

Development of Poly(L-Lactic Acid)/Chitosan/Basil Oil Active Packaging Films via a Melt-Extrusion Process Using Novel Chitosan/Basil Oil Blends

Following the global trend toward a cyclic economy, the development of a fully biodegradable active packaging film is the target of this work. An innovative process to improve the mechanical, antioxidant, and barrier properties of Poly(L-Lactic Acid)/Chitosan films is presented using essential basil oil extract. A Chitosan/Basil oil blend was prepared via a green evaporation/adsorption method as a precursor for the development of the Poly(L-Lactic Acid)/Chitosan/Basil Oil active packaging film. This Chitosan/Basil Oil blend was incorporated directly in the Poly(L-Lactic Acid) matrix with various concentrations. Modification of the chitosan with the Basil Oil improves the blending with the Poly(L-Lactic Acid) matrix via a melt-extrusion process. The obtained Poly(L-Lactic Acid)/Chitosan/Basil Oil composite films exhibited advanced food packaging properties compared to those of the Poly(L-Lactic Acid)/Chitosan films without Basil Oil addition. The films with 5%wt and 10%wt Chitosan/Basil Oil loadings exhibited better thermal, mechanical, and barrier behavior and significant antioxidant activity. Thus, PLLA/CS/BO5 and PLLA/CS/BO10 are the most promising films to potentially be used for active packaging applications.

The influence of PBAT content in the nanocapsules preparation and its effect in essential oils release

Nanoencapsulation provides new alternatives for the food industry, enabling a controlled and slow release of active antimicrobial agents, such as essential oils (EO). Poly (butylene adipate-co-terephthalate) (PBAT) nanocapsules loaded with linalool EO were prepared using an extrusion method with 1, 3, and 5% w/v (PBAT to chloroform). Nanocapsules' sizes ranged from 100 to 250 nm and were spherical. The release profile was studied using an ethanoic medium over 24 h, and according to the Korsmeyer-Peppas model, a Fick diffusion mechanism was involved. FT-IR and thermogravimetric analyses confirmed EO encapsulation with an encapsulation efficiency of 55%, 71%, and 74% for 1, 3, and 5%, respectively. The results indicated that encapsulation depended on organic phase concentration, with higher PBAT contents achieving better results. The resulting nanocapsules had antimicrobial activity against E. coli, which could be extended to develop active packaging systems.

Biodegradable Antimicrobial Food Packaging: Trends and Perspectives

This review presents a perspective on the research trends and solutions from recent years in the domain of antimicrobial packaging materials. The antibacterial, antifungal, and antioxidant activities can be induced by the main polymer used for packaging or by addition of various components from natural agents (bacteriocins, essential oils, natural extracts, etc.) to synthetic agents, both organic and inorganic (Ag, ZnO, TiO2 nanoparticles, synthetic antibiotics etc.). The general trend for the packaging evolution is from the inert and polluting plastic waste to the antimicrobial active, biodegradable or edible, biopolymer film packaging. Like in many domains this transition is an evolution rather than a revolution, and changes are coming in small steps. Changing the public perception and industry focus on the antimicrobial packaging solutions will enhance the shelf life and provide healthier food, thus diminishing the waste of agricultural resources, but will also reduce the plastic pollution generated by humankind as most new polymers used for packaging are from renewable sources and are biodegradable. Polysaccharides (like chitosan, cellulose and derivatives, starch etc.), lipids and proteins (from vegetal or animal origin), and some other specific biopolymers (like polylactic acid or polyvinyl alcohol) have been used as single component or in blends to obtain antimicrobial packaging materials. Where the package's antimicrobial and antioxidant activities need a larger spectrum or a boost, certain active substances are embedded, encapsulated, coated, grafted into or onto the polymeric film. This review tries to cover the latest updates on the antimicrobial packaging, edible or not, using as support traditional and new polymers, with emphasis on natural compounds.

Development of ZnO/Na-Montmorillonite Hybrid Nanostructures Used for PVOH/ZnO/Na-Montmorillonite Active Packaging Films Preparation via a Melt-Extrusion Process

Nowadays, the shelf-life extension of foods is a topic of major interest because of its environmental and economic benefits. For this purpose, various methods like deep-freezing, ultra-high-temperature pasteurization, drying methods, use of chemicals, controlled-atmosphere preservation, ionizing irradiation, and were investigated. During the last years, the smart packaging for foods using natural biodegradable components is of great interest because it provides positive environmental fingerprint and high shelf-life extension. In the present work, a new nanostructured composite material, the ZnO/Na-Montmorillonite hybrid, was developed. The high antimicrobial properties of the 3-D ZnO material in combination with the high barrier and strength properties of the 2-D Na-Montmorillonite material provided a high promising component for food smart packaging applications. As an extra innovation of this process, the ZnO nanorods coated the external surface of the Na-Montmorillonite and it was not intercalated into the clay as a pillaring material. This new material was incorporated with a 3% w/w composition with a biodegradable poly(vinyl)alcohol (PVOH) polymeric matrix which also exhibits antimicrobial activity. The final product was tested via XRD, FTIR, SEM, tensile test, water sorption, water vapor permeability, oxygen permeability UV–vis, and anti-microbial activity tests and it exhibited advanced mechanical and antimicrobial properties, especially for a ZnO/Na-Montmorillonite fraction of 4:1.