Chitosan-Based Active Packaging Films Incorporating Terminalia catappa Leaf Extract and Zinc Oxide Precursors for Sustainable Food Packaging

Chitosan-based active films containing microwave-extracted Terminalia catappa leaf extract (TE) and hydrothermally synthesised zinc oxide were developed and characterised. The selected extraction condition (440 W, 20 min, followed by freeze drying) gave 29.5% extract recovery and a total phenolic content of 639.5 mg GAE/g extract. Structural analyses showed that the original crystalline ZnO phase was no longer detectable after film formation under acidic casting conditions, whereas zinc remained present in the film matrix, indicating acid-mediated dissolution and/or structural transformation during casting. Zinc-containing films exhibited higher tensile strength (up to 36.0 MPa), increased glass transition temperature (up to 122.9 °C), and reduced moisture content and water vapour transmission. TE contributed antioxidant activity and light-shielding properties, with antioxidant capacity reaching 22.1 mg Trolox/g film. Films containing ≥0.2% initial ZnO also showed disc-diffusion antimicrobial activity against Escherichia coli (up to 22.7 mm) and Staphylococcus aureus (up to 20.7 mm). A preliminary 7-day banana-wrapping study further suggested that intermediate formulations containing 0.1–0.2% TE and 0.2–0.3% initial ZnO provided a useful balance among mechanical performance, optical properties, antimicrobial activity, and visual preservation. Overall, zinc–polyphenol–chitosan interactions played an important role in governing film structure and functionality.