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The high accumulation of plastic waste in the environment has led to great interest in biodegradable polymers, such as polylactic acid (PLA) or polyhydroxyalkanoates (PHAs). Their benefits, combined with the application of electrospinning technology, represent an innovative proposal for the food packaging industry. This article provides a comprehensive review of the latest developments of PLA- and PHA-biopolyester-based electrospun materials for food packaging applications, summarizing the reported technologies, material properties, applications, and invention patents. In addition, the legislation used to assess their biodegradability is also detailed. Electrospun packaging materials are largely developed through uniaxial, coaxial, emulsion, multiaxial, and needleless techniques. PLA- and PHA-biopolyester-based electrospun materials can be obtained as single and multilayer packaging structures, and the incorporation of natural extracts, organic compounds, and nanoparticles has become a great strategy for designing active food packaging systems. The biodegradability of electrospun materials has mainly been evaluated in soil, compost, and aquatic systems through ASTM and ISO normatives. In this review, the dependence of the biodegradation process on the polymer type, conditions, and test methods is clearly reviewed. Moreover, these biodegradable electrospun materials have shown excellent antioxidant and antimicrobial properties, resulting in a great method for extending the shelf life of fruits, bread, fish, and meat products.

The performance characteristics of polylactic acid (PLA) as an active food packaging film can be highly influenced by the incorporation of active agents (AAs) into PLA, and the type of processing technique. In this review, the effect of processing techniques and the addition of natural AAs on the properties related to PLA performance as a packaging material are summarized and described through a systematic analysis, giving new insights about the relation between processing techniques, types of AA, physical–mechanical properties, barriers, optical properties, compostability, controlled release, and functionalities in order to contribute to the progress made in designing antioxidant and antimicrobial PLA packaging films. The addition of AAs into PLA films affected their optical properties and influenced polymer chain reordering, modifying their thermal properties, functionality, and compostability in terms of the chemical nature of AAs. The mechanical and barrier performance of PLA was affected by the AA’s dispersion degree and crystallinity changes resulting from specific processing techniques. In addition, hydrophobicity and AA concentration also modified the barrier properties of PLA. The release kinetics of AAs from PLA were tuned, modifying diffusion coefficient of the AAs in terms of the different physical properties of the films that resulted from specific processing techniques. Several developments based on the incorporation of antimicrobial and antioxidant substances into PLA have displayed outstanding activities for food protection against microbial growth and oxidation.

This study aimed to enhance the properties and compostability of active poly(lactic acid) (PLA) films by incorporating β-cyclodextrin (β-CD) inclusion complexes with allyl isothiocyanate (AITC). Films were prepared using melt extrusion and characterized based on their structural, chemical, morphological, thermal, and barrier properties. These inclusion complexes improved the thermal stability and moisture absorption of films, enhancing disintegration under composting conditions. The release of AITC in the vapor phase was responsive to relative humidity, maintaining the antimicrobial functionality at low values and releasing effectively at higher humidity levels, with a maximum release at 100%. Incorporating 5% and 10% β-CD:AITC complexes accelerated disintegration under composting conditions, reducing the time by 5 days for disintegration compared to pure PLA, achieving up to 90% in 23 days. These results, with a general improvement in functional properties, suggest that PLA films with β-CD:AITC are promising for developing sustainable, biodegradable antimicrobial packaging solutions for food applications.

The search for and synthesis of new antimicrobial nanostructures is important to reduce microbial incidence that induces infectious diseases and to aid in the antibiotic resistance crisis, which are two of the most pressing issues in global public health. In this work, novel, hollow, calcined titanium dioxide nanospheres (CSTiO 2 ) were successfully synthesized for the first time through the combination of electrospinning and atomic layer deposition techniques. Poly(vinylpyrrolidone) (PVP) electrosprayed spherical particles were double-coated with alumina and titanium dioxide, and after a calcination process, hollow nanospheres were obtained with a radius of approximately 345 nm and shell thickness of 17 nm. The structural characterization was performed using electron microscopy, and X-ray diffraction and small-angle X-ray diffraction evidenced an anatase titanium dioxide crystalline structure. Thermogravimetric analysis and Fourier-transform infrared spectroscopy studies demonstrated the absence of polymer residue after the calcination process. The antimicrobial properties of the developed CSTiO 2 hollow nanospheres were evaluated against different bacteria, including resistant E. coli and S. aureus strains, and when compared to commercial TiO 2 nanoparticles, CSTiO 2 nanospheres exhibited superior performance. In addition, the positive effect of UV irradiation on the antimicrobial activity was demonstrated.

Cellulose stands out as a promising alternative to conventional polymers in food packaging due to its abundance, renewability, biodegradability and structural robustness. Despite these advantages, its natural low resistance to water and fats limits its direct application, necessitating the use of protective coatings to enhance its functionality. In this context, the use of biopolymeric coatings such as poly(lactic acid) (PLA), starch, lignin, chitin and chitosan has emerged as a sustainable solution, providing effective barriers against moisture and oils. These coatings not only improve the functional performance of cellulosic substrates but also reduce reliance on fossil-based plastics, fostering compostable systems and supporting a circular economy. This review analyzes recent developments in biopolymer-coated cellulosic packaging materials, focusing on their resistance to water and fats. The aim is to assess their potential for sustainable food packaging applications. The findings highlight how these innovations contribute to global sustainability goals, such as reducing plastic waste, lowering carbon emissions, and decreasing dependence on non-renewable resources.

β-cyclodextrin and allyl isothiocyanate inclusion complexes (β-CD:AITC) have been proposed for developing fresh fruit and vegetable packaging materials. Therefore, the aim of this research was to develop active materials based on poly(lactic acid) (PLA) loaded with β-CD:AITC and to assess changes in the material properties during the release of AITC to food simulants. PLA films with 0, 5 and 10 wt.% β-CD:AITC were developed by extrusion. Surface properties were determined from contact angle measurements. Films were immersed in water, aqueous and fatty simulants to assess the absorption capacity and the change in the thermal properties. Moreover, the release of AITC in both simulants was evaluated by UV-spectroscopy and kinetic parameters were determined by data modeling. Results showed that a higher concentration of β-CD:AITC increased the absorption of aqueous simulant of films, favoring the plasticization of PLA. However, the incorporation of β-CD:AITC also avoided the swelling of PLA in fatty simulant. These effects and complex relationships between the polymer, inclusion complexes and food simulant explained the non-systematic behavior in the diffusion coefficient. However, the lower partition coefficient and higher percentage of released AITC to the fatty simulant suggested the potential of these materials for high-fat fruit and vegetable active packaging applications.

The açaí fruit (Euterpe oleracea Mart.) is well known for its high content of antioxidant compounds, especially anthocyanins, which provide beneficial health properties. The incorporation of this fruit is limited to food products whose processing does not involve the use of high temperatures due to the low thermal stability of these functional components. The objective of this work was the encapsulation of açaí fruit antioxidants into electrosprayed zein, a heat-resistant protein, to improve their bioavailability and thermal resistance. First, the hydroalcoholic açaí extract was selected due to its high polyphenolic content and antioxidant capacities, and, subsequently, it was successfully encapsulated in electrosprayed zein particles. Scanning electron microscopy studies revealed that the resulting particles presented cavities with an average size of 924 nm. Structural characterization by Fourier transform infrared spectroscopy revealed certain chemical interaction between the active compounds and zein. Encapsulation efficiency was approximately 70%. Results demonstrated the effectiveness of the encapsulated extract on protecting polyphenolic content after high-temperature treatments, such as sterilization (121 °C) and baking (180 °C). Bioaccesibility studies also indicated an increase of polyphenols presence after in vitro digestion stages of encapsulated açaí fruit extract in contrast with the unprotected extract.

The design of biodegradable polymeric materials is of increasing scientific interest due to accelerating levels of plastics pollution. One area of increasing interest is the design of biodegradable polymer films based on seaweed as a raw material. The goal of the study is to explore whether machine learning techniques can be used to predict the properties of unknown compositions based on existing data from the literature. Clustering algorithms are used, which show how some ingredients components at certain concentration levels alter the mechanical properties of the films. Robust regression algorithms with three popular models, namely decision tree, random forest, and gradient boosting. Their predictive capabilities are compared, resulting in the random forest algorithm being the most stable with the greatest predictive capacity. These analyses offer a decision support system for biomaterials manufacturing and experimentation. The results and conclusions of the study indicate that bioplastics made from seaweed have promising potential as a sustainable alternative to traditional plastics, discovering interesting additives to improve the performance of biopolymers. In addition, the machine learning approaches used provide effective tools for analyzing and predicting the properties of these materials in structured but highly sparse data.

The main objective of this work was to study the release of cinnamaldehyde (CIN) from electrospun poly lactic acid (e-PLA) mats obtained through two techniques: (i) direct incorporation of active compound during the electrospinning process (e-PLA-CIN); and (ii) supercritical carbon dioxide (scCO2) impregnation of CIN within electrospun PLA mats (e-PLA/CINimp). The development and characterization of both of these active electrospun mats were investigated with the main purpose of modifying the release kinetic of this active compound. Morphological, structural, and thermal properties of these materials were also studied, and control mats e-PLA and e- PLA CO 2 were developed in order to understand the effect of electrospinning and scCO2 impregnation, respectively, on PLA properties. Both strategies of incorporation of this active compound into PLA matrix resulted in different morphologies that influenced chemical and physical properties of these composites and in different release kinetics of CIN. The electrospinning and scCO2 impregnation processes and the presence of CIN altered PLA thermal and structural properties when compared to an extruded PLA material. The incorporation of CIN through scCO2 impregnation resulted in higher release rate and lower diffusion coefficients when compared to active electrospun mats with CIN incorporated during the electrospinning process.

The food industry has a current challenge of increasing the recycling of post-consumer plastics to reduce plastic waste towards a circular economy, especially flexible polypropylene, which is highly demanded in food packaging. However, recycling post-consumer plastics is limited because service life and reprocessing degrade their physical-mechanical properties and modify the migration of components from the recycled material to the food. This research evaluated the feasibility of valorization of post-consumer recycled flexible polypropylene (PCPP) by incorporating fumed nanosilica (NS). For this purpose, the effect of concentration and type (hydrophilic and hydrophobic) of NS on the morphological, mechanical, sealing, barrier and overall migration properties of PCPP films was studied. Incorporating NS improved Young’s modulus and, more significantly, tensile strength at 0.5 wt% and 1 wt%, where a better particle dispersion was confirmed by EDS-SEM, but it diminished elongation at breakage of the films. Interestingly, NS tended to increase the seal strength of PCPP nanocomposite films more significantly at higher NS content, showing a seal failure of the adhesive peel type which is preferred for flexible packaging. NS at 1 wt% did not affect the water vapor and oxygen permeabilities of the films. Overall migration of PCPP and nanocomposites exceeded the limit value of 10 mg dm−2 allowed by European legislation at the studied concentrations of 1% and 4 wt%. Nonetheless, NS reduced the overall migration of PCPP from 17.3 to 15 mg dm−2 in all nanocomposites. In conclusion, PCPP with 1 wt% of hydrophobic NS presented an improved overall performance of the studied packaging properties.