Packaging demand currently exceeds 144 Mt per year, of which >90% is conventional plastic, generating over 100 Mt of waste and 1.8 Gt CO2-eq emissions annually. In this review, we systematically survey three classes of lignocellulosic feedstocks, agricultural residues, fruit and vegetable by-products, and forestry wastes, with respect to their physicochemical composition (cellulose crystallinity, hemicellulose ratio, and lignin content) and key processing pathways. We then examine fabrication routes (solvent casting, extrusion, and compression molding) and quantify how compositional variables translate into film performance: tensile strength, elongation at break (4–10%), water vapor transmission rate, thermal stability, and biodegradation kinetics. Highlighted case studies include the reinforcement of poly(vinyl alcohol) (PVA) with 7 wt% oxidized nanocellulose, yielding a >90% increase in tensile strength and a 50% reduction in water vapor transmission rate (WVTR), as well as pilot-scale extrusion of rice straw/polylactic acid (PLA) blends. We also assess techno-economic metrics and life-cycle impacts. Finally, we identify four priority research directions: harmonizing pretreatment protocols to reduce batch variability, scaling up nanocellulose extraction and film casting, improving marine-environment biodegradation, and integrating circular economy supply chains through regional collaboration and policy frameworks.
Kossalbayev et al. (Fri,) studied this question.
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