Polyvinyl Alcohol Biopolymer Composites for Active Biodegradable Food Packaging, Current Trends and Future Prospective: A Review

Polyvinyl alcohol (PVA), a synthetic, non-toxic, biodegradable polymer with good thermal, barrier, and mechanical properties, is a leading candidate for the fabrication of eco-friendly food packaging. However, the practical application of PVA for food packaging is limited by its high hydrophilicity, moisture sensitivity, and poor UV shielding efficiency. To overcome these limitations, recent research has focused on polymer blending and the incorporation of fillers and natural additives into the composites. This review critically evaluates how intermolecular interactions, crystallinity, filler dispersion, and crosslinking mechanisms govern the structure–property–application relationships in PVA-based active packaging systems. Comparative evaluation across studies indicates that blending with biopolymers improves the mechanical, thermal, and barrier properties, while different additives and fillers also impart antimicrobial, antioxidant, and UV shielding activities to the films, essential for active packaging applications. The review also highlights the trade-offs associated with filler dispersion, processing complexity, and cost that hinder large-scale application. In addition, critical challenges related to nanofiller toxicity, migration, scalability, and commercial feasibility are discussed to provide a balanced perspective on applicability. By integrating recent developments with comparative and mechanistic insights, this review establishes key design strategies for optimising PVA-based bio-composites and identifies future research directions toward scalable, high-performance, and environmentally sustainable food packaging materials.