Enhanced sustainable packaging solutions through corn stover‐reinforced polypropylene biomass composites: Characterization, performance, and potential applications

Abstract This research systematically explores the use of corn stover (CS) with polypropylene (PP) and modified polypropylene (MPP) for sustainable food packaging. MPP is produced via melt mixing with dicumyl peroxide followed by maleic anhydride. The study aims to assess the potential of these biomass composites in eco‐friendly packaging applications. Our comprehensive evaluations include crystalline behavior, water absorption rate, contact angle, water vapor permeation coefficients, and oxygen transmission rates. Notably, at 20% CS content, the tensile strength of the MPP/CS composite material is about 120% higher than PP/CS composites. We also observed that CS significantly alters key properties of PP and MPP. The weight loss analysis of vegetables and water vapor transmission rate tests indicate that the MPP/CS composite film with 20% CS has the best effect on water vapor barrier and preservation of vegetables. Additionally, microbial growth analysis reveals that Escherichia coli and Staphylococcus aureus grow less abundantly on composites with lower CS contents, and MPP/CS composites show reduced microbial growth compared to PP/CS. This integrated study demonstrates the optimization of composite material performance through CS variables, revealing innovative potential for CS in enhancing PP and guiding the design of future sustainable packaging materials. Highlights 20% CS in MPP/CS boosts tensile strength by 120% versus PP/CS composites. 20% CS in MPP/CS gives optimal water vapor barrier and veggie preservation. MPP/CS reduces E. coli and S. aureus growth better than PP/CS, especially at low CS. MPP's functional group enhances CS compatibility, dispersion, structure, and crystallinity. Corn stover‐reinforced PP composites offer a sustainable, eco‐friendly packaging option.