Coffee by-product cascara as an edible active coating for enhancing hazelnut preservation and packaging

Edible active packaging is an innovative solution that extends the shelf life of products, protect it from contamination, and prevent oxidation, without contributing to additional packaging waste. Here this study explores the potential of utilizing cascara extract, a coffee by-product rich in polyphenols and polysaccharides, as a sustainable material for preserving roasted hazelnuts. Gelatin and glycerol are investigated as additives to enhance film properties. Optimal formulations were exhibited promising barrier performance, antioxidant activity and low surface energy. Based on Response Surface Methodology (RSM), the formulation consisted of 5.1 % w/v gelatin as the primary film-forming agent, 89.2 % w/v cascara extract as an active component, 5.7 % w/v glycerol as a plasticizer, showed the highest oxygen barrier property. Accelerated shelf-life testing (ASLT) at 35 and 45 °C indicated selected cascara coating potentially doubling hazelnut shelf life. The cascara edible coating had a brown film appearance which can be acceptable for dark coloured food products in future application. Despite deviations in color, cascara offers potential for sustainable packaging, opening avenues for innovative solutions. • Gelatine based coatings with cascara and glycerol effectively double hazelnut shelf life. • Optimum gelatin and glycerol in cascara extract showed promising barrier properties. • Promising antioxidant activity retained in all formulations. • Cascara active edible coatings showed potential as sustainable food packaging.