Valorization of plant-based agro-waste into sustainable food packaging materials: Current approaches and functional applications

There is an increasing demand for sustainable food packaging solutions, leading to the valorization of plant-based agro-waste into biodegradable, flexible, and functional materials. This review comprehensively covers state-of-the-art methods and advances for converting agro-industrial waste into high-performance packaging materials, focusing on biopolymers such as cellulose, hemicellulose, starch, pectin, lignin, chitosan, alginate, and polyhydroxyalkanoates (PHAs). They are characterized by favorable mechanical, barrier, bioactive, and degradation properties, aligning with circular bioeconomy principles by reducing dependence on fossil-based plastics and minimizing waste. These agro-waste-derived materials ensure food safety, extend shelf life, and enable active and intelligent packaging through bioactive compound incorporation, improving antimicrobial and antioxidant properties while reducing environmental burdens. This review spotlights advanced processing and fabrication techniques, including solvent casting, melt extrusion, electrospinning, compression molding, and layer-by-layer assembly, while addressing key technological, economic, and regulatory barriers to scalability. Additionally, the review explores the valorization of diverse plant-based wastes (stem, leaf, fruit and vegetable, seed and shell, root and tuber) for biopolymer extraction, contributing to the development of biodegradable packaging solutions that reduce carbon footprints and environmental pollution. The implementation of these innovative agro-waste-based packaging materials supports global sustainability and SDGs, providing a pathway towards a resilient, circular food system.