Scalability, biodegradability, and mechanistic insights of leaf protein based nanofibers through needleless electrospinning

This study systematically demonstrated the interrelation between the solution-state rheological and surface behaviour of polyvinyl alcohol (PVA) to moringa leaf protein concentrate (MLPC: 0–3%) blends and their resultant solid-state attributes of nanofiber. Nanofibers were produced from PVA-MLPC blends using a needleless electrospinning process at 26 kV, a 14 cm electrode–collector gap, and a feed rate of 6 mL h⁻¹ , followed by thermal crosslinking at 120°C for 3 h. Increasing MLPC concentration systematically decreased solution viscosity and enhanced electrical conductivity (from 0.8 to 5.1 mS/m), thereby refining the fiber morphology by reducing the average diameter from 2291 nm to a uniform 635 nm at an optimal 2% MLPC concentration. Thermal treatment produced a denser, more interconnected fiber network, accompanied by a maximum tensile strength of 13.91 MPa and an increase in the water contact angle from 49.5° to 77.5 °. However, MLPC concentrations above 2% caused jet instability and bead formation, reducing production yield from 91.4% to 66.0%. Multivariate analysis further showed strong associations among solution properties, morphology, yield, and functional performance. Overall, 1–2% MLPC provided the most favorable balance between spinnability and material performance. The results support the potential of PVA–MLPC nanofibers as biodegradable packaging-material candidates, while pilot-scale operation, energy and cost analysis, food-contact safety, and validation in actual food systems remain necessary before industrial or food-packaging performance can be established.