In this work, alpha-tocopherol (α-TOC) was encapsulated in poly(lactic acid) nanoparticles (PLA NPs) and added to low-density polyethylene (LDPE) films with the aim of producing an active film for food packaging applications. PLA NPs loaded with α-TOC were produced through nanoprecipitation and dried using two methods (freeze-dryer and oven). LDPE-based films with final polymeric matrix concentrations of 10 and 20 g/kg were then produced through blow extrusion. The results showed that LDPE-based films loaded with α-TOC can be produced using blow extrusion, and a good distribution of PLA NPs can be obtained within the LDPE matrix as observed using scanning electron microscopy (SEM). The mechanical properties were affected by the incorporation of α-TOC and PLA NPs loaded with α-TOC, with the observation of a decrease in tensile strength and Young’s Modulus values and an increase in elongation at break. Regarding water vapor permeability, the films showed a reduction in the values with the addition of α-TOC and PLA NPs loaded with α-TOC compared to the LDPE film (control). Films with α-TOC in the free state and loaded in PLA NPs showed antioxidant activity, but their behavior was affected by the encapsulation process.

Active food packaging is a dynamic area where the scientific community and industry have been trying to find new strategies to produce innovative packaging that is economically viable and compatible with conventional production processes. The materials used to develop active packaging can be organized into scavenging and emitting materials, and based on organic and inorganic materials. However, the incorporation of these materials in polymer-based flexible packaging is not always straightforward. The challenges to be faced are mainly related to active agents’ sensitivity to high temperatures or difficulties in dispersing them in the high viscosity polymer matrix. This review provides an overview of methodologies and processes used in the production of active packaging, particularly for the production of active flexible films at the industrial level. The direct incorporation of active agents in polymer films is presented, focusing on the processing conditions and their effect on the active agent, and final application of the packaging material. Moreover, the incorporation of active agents by coating technologies and supercritical impregnation are presented. Finally, the use of carriers to help the incorporation of active agents and several methodologies is discussed. This review aims to guide academic and industrial researchers in the development of active flexible packaging, namely in the selection of the materials, methodologies, and process conditions.

Active food packaging is a dynamic area where the scientific community and industry have been trying to find new strategies to produce innovative packaging that is economically viable and compatible with conventional production processes. The materials used to develop active packaging can be organized into scavenging and emitting materials, and based on organic and inorganic materials. However, the incorporation of these materials in polymer-based flexible packaging is not always straightforward. The challenges to be faced are mainly related to active agents' sensitivity to high temperatures or difficulties in dispersing them in the high viscosity polymer matrix. This review provides an overview of methodologies and processes used in the production of active packaging, particularly for the production of active flexible films at the industrial level. The direct incorporation of active agents in polymer films is presented, focusing on the processing conditions and their effect on the active agent, and final application of the packaging material. Moreover, the incorporation of active agents by coating technologies and supercritical impregnation are presented. Finally, the use of carriers to help the incorporation of active agents and several methodologies is discussed. This review aims to guide academic and industrial researchers in the development of active flexible packaging, namely in the selection of the materials, methodologies, and process conditions.

To preserve food from moisture and oxygen, polymers, such as ethylene vinyl alcohol (EVOH) are used in multilayer structures to provide oxygen barrier, while low-density polyethylene (LDPE) is used for a water vapor barrier. While this material combination is functionally ideal, it may not comply with the new packaging recycling guidelines. Some European markets have implemented rules that limit the weight percentage of EVOH in LDPE films. One way to increase recyclability is by reducing the amount of EVOH in the film structure while maintaining the packaging's oxygen barrier properties. To achieve this, it is necessary to improve the barrier properties of EVOH. With this objective in mind, this study evaluated the incorporation of nanoclays (NC), cellulose microcrystals (MCC), silicon dioxide nanoparticles (SiO2), and cellulose nanocrystals (CNC) into an EVOH matrix. The results indicate that NC and MCC facilitate a stable blown film extrusion process and have a better dispersion in the EVOH matrix. Based on this finding, three-layer films (with an ABA configuration) consisting of LDPE (A) and EVOH (7 μm layer) with 0.5 or 1 wt.% MCC or NC (B) were produced to protect the EVOH from moisture and enable blown film processing. The oxygen transmission rate (OTR) values were lowest for 0.5 wt.% NC and 1 wt.% MCC incorporation. Although the films with micro and nanoparticles had increased haze, this did not affect the visibility of the packaged food.

β-carotene loaded bio-based nanoparticles (NPs) were produced by the solvent-displacement method using two polymers: zein and ethylcellulose. The production of NPs was optimised through an experimental design and characterised in terms of average size and polydispersity index. The processing conditions that allowed to obtain NPs (<100 nm) were used for β-carotene encapsulation. Then β-carotene loaded NPs were characterised in terms of zeta potential and encapsulation efficiency. Transmission electron microscopy, Fourier transform infrared spectroscopy and X-ray diffraction analysis were performed for further morphological and chemical characterisation. In the end, a static in vitro digestion following the INFOGEST protocol was performed and the bioaccessibility of β-carotene encapsulated in both NPs was determined. Results show that the best conditions for a size-controlled production with a narrow size distribution are lower polymer concentrations and higher antisolvent concentrations. The encapsulation of β-carotene in ethylcellulose NPs resulted in nanoparticles with a mean average size of 60 ± 9 nm and encapsulation efficiency of 74 ± 2%. β-carotene loaded zein-based NPs resulted in a mean size of 83 ± 8 nm and encapsulation efficiency of 93 ± 4%. Results obtained from the in vitro digestion showed that β-carotene bioaccessibility when encapsulated in zein NPs is 37 ± 1%, which is higher than the value of 8.3 ± 0.1% obtained for the ethylcellulose NPs.