Scalable food-grade modification of sepiolite for long-term controlled release of clove oil in LDPE active packaging films

The incorporation of volatile bioactive compounds into polymeric materials remains a key challenge for the development of industrially active packaging. In this work, a scalable and food-grade strategy is presented for the stabilization and controlled release of clove essential oil (CO) using organo-modified sepiolite as a fibrous clay carrier. Sepiolite was functionalized with octadecylamine (ODA) under mild, food-compatible conditions, assisted by fumaric acid (E−297), enabling the preparation of multicomponent nanomaterials (MCNMs) suitable for melt processing. The MCNMs exhibited enhanced thermal stability and controlled CO retention, with aging tests indicating a loss of approximately 10% after 14 days under ambient conditions, consistent with diffusion-controlled release at the carrier level. The hybrid materials were subsequently compounded into Low Density Polyethylene (LDPE) by extrusion blow molding at filler loadings of 0.5, 1, and 2 wt%, yielding composite films with optical, thermal, and mechanical properties comparable to neat LDPE. Overall migration tests using simulants A (10% ethanol) and D1 (50% ethanol) confirmed compliance with EU Regulation No. 10/2011 for food-contact plastics. Long-term aging revealed that approximately 33% of the initially loaded clove oil was retained in the LDPE-MCNM films after three years of storage at room temperature, while maintaining a detectable aroma. The limited indicate effective confinement of the essential oil within the clay-polymer system, preventing premature diffusion. Unlike conventional encapsulation strategies, the proposed approach combines industrial scalability, food-grade chemistry and reduced loss of volatile compounds within a single processing route. Overall, this work demonstrates a process-compatible approach for integrating essential oil-clay hybrids into polyolefin matrices, providing a realistic pathway toward industrially active packaging materials. • Food-grade organo-modified sepiolite was developed as a carrier for clove essential oil. • Fumaric-acid-assisted organomodification enables mild and scalable clay functionalization. • Semi-wet kneading reduces water, energy demand and oil losses vs. wet routes. • Multicomponent nanomaterials were melt-processable into Low Density Polyethylene films without compromising key properties. • Long-term aging showed sustained aroma retention and regulatory compliance.