Engineering Bacterial Cellulose Based Films: Recent Advances in Functional Modification for Packaging Applications

Bacterial cellulose (BC), a biopolymer with fibrous nanoscale structure, high purity, crystallinity, and strong mechanical properties, is promising for sustainable biomedical, environmental, and food packaging. However, its hydrophilicity, moisture sensitivity, limited functional groups, and poor thermal processability limit its use in advanced packaging. Recent studies focus on surface treatments, chemical modifications, and polymer blends to overcome these issues while maintaining structure. Physical methods like non-thermal plasma and UV radiation alter surface energy and enhance adhesion without solvents. Chemical modifications such as esterification, silanization, and TEMPO oxidation improve hydrophobicity, reactivity, and compatibility with bioactive substances by functionalizing fibrils while keeping nanofibrous structure. Polymer blending boosts flexibility, barrier properties, and processability, creating composites. Natural polymer blends, like chitosan, starch, and alginate, enhance ductility, antimicrobial properties, and moisture control. Synthetic polymer blends, especially with PVA, significantly increase strength, stability, and processability. Overall, these methods effectively balance mechanical, barrier, and functional improvements, highlighting their potential for scalable application. This review integrates advancements documented since 2021, and critically evaluates the structural, physicochemical, and functional alterations that designate refined BC as a sustainable, viable option for food packaging.