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A new active coating was developed by using Cucumis metuliferus fruit extract as antioxidant additive with the aim of obtaining an easy way to functionalize low-density polyethylene (LDPE) films for food packaging applications. Thus, an extraction protocol was first optimized to determine the total phenolic compounds and the antioxidant activity of CM. The aqueous CM antioxidant extract was then incorporated into cellulose acetate (CA) film-forming solution in different concentrations (1, 3 and 5 wt.%) to be further coated in corona-treated LDPE to obtain LDPE/CA-CM bilayer systems. CA and CA-CM film-forming solutions were successfully coated onto the surface of LDPE, showing good adhesion in the final bilayer structure. The optical, microstructural, thermal, mechanical and oxygen barrier performance, as well as the antioxidant activity, were evaluated. The active coating casted onto the LDPE film did not affect the high transparency of LDPE and improved the oxygen barrier performance. The antioxidant effectiveness of bilayer packaging was confirmed by release studies of Cucumis metuliferus from the cellulose acetate layer to a fatty food simulant. Finally, the LDPE/CA-CM active materials were also tested for their application in minimally processed fruits, and they demonstrated their ability to reduce the oxidation process of fresh cut apples. Thus, the obtained results suggest that CA-CM-based coating can be used to easily introduce active functionality to typically used LDPE at industrial level and enhance its oxygen barrier, without affecting the high transparency, revealing their potential application in the active food packaging sector to extend the shelf-life of packaged food by prevention of lipid oxidation of fatty food or by prevention fruit browning.

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This article proposes a foaming method using supercritical carbon dioxide (scCO2) to obtain compostable bionanocomposite foams based on PLA and organoclay (C30B) where this bionanocomposite was fabricated by a previous hot melt extrusion step. Neat PLA films and PLA/C30B films (1, 2, and 3 wt.%) were obtained by using a melt extrusion process followed by a film forming process obtaining films with thicknesses between 500 and 600 μm. Films were further processed into foams in a high-pressure cell with scCO2 under constant conditions of pressure (25 MPa) and temperature (130 °C) for 30 min. Bionanocomposite PLA foams evidenced a closed cell and uniform cell structure; however, neat PLA presented a poor cell structure and thick cell walls. The thermal stability was significantly enhanced in the bionanocomposite foam samples by the good dispersion of nanoclays due to scCO2, as demonstrated by X-ray diffraction analysis. The bionanocomposite foams showed improved overall mechanical performance due to well-dispersed nanoclays promoting increased interfacial adhesion with the polymeric matrix. The water uptake behavior of bionanocomposite foams showed that they practically did not absorb water during the first week of immersion in water. Finally, PLA foams were disintegrated under standard composting conditions at higher rates than PLA films, showing their sustainable character. Thus, PLA bionanocomposite foams obtained by batch supercritical foaming seem to be a sustainable option to replace non-biodegradable expanded polystyrene, and they represent a promising alternative to be considered in applications such as food packaging and other products.

Microcellular nanocomposite foams functionalized with cinnamaldehyde (Ci) were obtained through two-step supercritical foaming and impregnation processing. PLA nanocomposite foams with different C30B concentrations (1, 2, and 3 wt.%) were obtained by foaming with scCO2 at 25 MPa and 135 °C and impregnated with Ci at 12 MPa and 40 °C. The effect of the C30B content and Ci incorporation on the morphological, structural, thermal, and release properties of the developed foams were investigated. The incorporation of Ci was not influenced by C30B’s addition. The presence of C30B and Ci incorporation reduced the average pore diameter slightly and the crystallinity degree of the foams extensively. Simultaneously, the experimental and theoretical characterization of the Ci release from the PLA nanocomposite foams in EtOH 50% was analyzed. The mechanism of Ci release from the foams was defined as a quasi-Fickian diffusion process that could be successfully described using the Korsmeyer–Peppas model. The active PLA foams presented a higher potential of migration and faster release when compared with that reported in commonly used PLA films, showing that biopolymeric foams could be potentially used as active food packaging to improve the migration of active compounds with low migration potentials in order to improve their biological activity in foods.