Sustainable active packaging via bio-functionalized cloth bags containing peppermint oil-chitosan biocomposites for sesame seed preservation

Meeting international consumer demand now requires a dual approach of adopting eco-friendly farming practices while keeping chemical residues strictly below target MRL values. The increasing demand for produce that limits residues to below maximum acceptable levels and concerns over the environmental impacts of conventional pesticides necessitate the development of safe, sustainable, and cost-effective storage technologies. This study reports a bio-functionalization approach using chitosan-encapsulated peppermint oil biocomposite (BPO) to transform the passive cloth bag into an eco-friendly active packaging system for sesame seed storage and also studied the effect of bio-functionalised cloth bags against Triboilum castaneum (Tenebrionidae: Coleoptera). The biocomposite was synthesized using covalent crosslinking and exhibited high encapsulation efficiency (94.9%), controlled release behaviour consistent with the Korsmeyer-Peppas kinetic model and strong antioxidant stability. Successful encapsulation was confirmed through scanning electron microscopy. Storage evaluations conducted over six months demonstrated bio-functionalised cloth bag with BPO effectively enhanced storage performance by significantly reducing insect mediated deterioration minimal weight loss (0.36%) and seed damage (1.83%) and preserved seed quality parameters such as germination (98.30%) and vigour index (1228.00) without altering the intrinsic biochemical composition of seeds. These improvements was attributed to the combined and complementary effects of peppermint oil bioactivity, modified atmosphere generation and sustained antioxidant functionality of the biocomposite. Overall, the findings establish cloth bag bio-functionalization approach is a easy, effective sustainable active packaging strategy that improves storage protection without compromising seed quality. The favourable benefit-cost ratio (1.80:1) highlight economic feasibility for small and marginal stakeholders. This approach shows strong potential for export-oriented seed preservation and compliance with international standards, offering a viable alternative to synthetic fumigants within sustainable food storage systems.