A Critical Review of Emerging Solutions for Food Packaging: Opportunities and Challenges

The environmental impact of conventional plastics has driven a shift toward biobased food packaging, shaped by consumer expectations, market trends, and regulatory policies within the European Union (EU). Despite extensive research on biopolymers such as starch, cellulose, chitosan, and polylactic acid (PLA), their use in commercial food packaging remains limited. A major challenge identified in the literature is the evaluation of biopolymer performance, in which environmental benefits are often considered independently of mechanical, barrier, and economic factors. This review addresses this gap by critically exploring the functional performance of biopolymers regarding their chemical structure and processing methods, with particular emphasis on the role of bioactive compounds in enhancing these materials' properties. Although several biopolymers can achieve tensile strength values comparable to conventional petroleum-based plastics, their higher water vapor transmission rates remain an unsolved barrier to scalability. These limitations, together with challenges related to mechanical performance and production costs, are discussed to clarify their impact on industrial feasibility and to identify priorities for future research supporting scalable, cost-effective, and regulatory-compliant food packaging solutions.