Smart green packaging solutions for safe and sustainable food systems

Food safety, postharvest losses, and environmental sustainability remain persistent challenges in global food systems, particularly amid rapid population growth and complex supply chains. Additionally, conventional fossil-fuel-derived packaging remains the global norm despite its enormous contribution to greenhouse gas emissions and microplastic contamination. In light of these, the future of safe, surplus, and sustainable food lies in the convergence of innovative, viable, and accessible solutions. Green smart packaging– which combines bio-based, biodegradable materials with integrated sensing functions has emerged as a promising solution in response to these challenges. To address this critical gap, this comprehensive review synthesizes some of the latest advances (2020–2025) in green smart packaging, positioning it as a foundational technology for the Industry 5.0 transition sourced across major repositories. Although, existing studies are often fragmented by polymer type, food matrix, or sensor mechanism, this work categorically evaluates the efficacy of plant-based biopolymers (including cellulose, alginate, starch, pectin, and carrageenan) and animal-derived materials (such as chitosan, gelatin, and whey proteins) functionalized with natural extracts, essential oils, metal and metal oxide nanoparticles, nanocellulose, and colorimetric indicators. Key experimental outcomes across the reviewed materials demonstrate overall performance enhancements, achieving shelf-life extensions ranging from a few days to over 6 weeks, while reducing microbial loads by up to 3–4 log cycles. Significant improvements in mechanical strength, barrier properties, antimicrobial/antioxidant activity, and real-time freshness monitoring achieved by the combination these green materials biopolymers were also reported. Remarkably, this study presents a comprehensive framework that integrates bio-based materials, intelligent sensing, and Industry 5.0 principles. Taken together, this framework not only bridges scientific and industrial gaps but also positions sensor-embedded biodegradable packaging as a catalyst for achieving the United Nations Sustainable Development Goals (SDG 2: Zero Hunger, SDG 12: Responsible Consumption and Production, SDG 13: Climate Action).