Effect of migration on the functionality of zinc oxide nanoparticle in polybutylene adipate terephthalate/thermoplastic starch films: A food simulant study

Active packaging relies on controlled release of antimicrobials for food protection; however, uncontrolled migration due to environmental factors poses safety and functionality challenges. This study investigated the stability of zinc oxide nanoparticle (ZnONP) in poly(butylene-adipate-co-terephthalate)/thermoplastic starch (PBAT/TPS) biopolymer film for active food packaging applications. While incorporating ZnONP significantly enhanced the properties and active functionalities (UV-light blocking, antimicrobial activity) of PBAT/TPS film, food simulants posed significant stability challenges. Notably, exposure to 3 % acetic acid (acidic food simulant) triggered complete detachment and dissolution of ZnONPs from the film surface, leading to pore formation and subsequent internal ZnO dissolution. This resulted in dramatic alterations to the bionanocomposite films, including increased opacity, water vapor permeability, and decreased thermal stability, mechanical properties, and active functionalities. In contrast, 10 % ethanol (aqueous food simulant) had minimal impact, suggesting higher ZnO stability in neutral environments. Importantly, ZnO migration analysis revealed thresholds for safe application: 1 % ZnONP for acidic food contact and up to 5 % for aqueous foodstuffs. These findings highlight the critical role of environmental factors in ZnONP stability and emphasize the need for strategic optimization of ZnO content for achieving both functionality and safety in active biopolymer packaging.