Enhanced extraction of bioactive compounds from tea waste for sustainable polylactide-based bioplastic applications in active food packaging

Active and sustainable food packaging materials were prepared through solvent casting, by blending tea waste (TW) extract rich in bioactive molecules with a neat polylactide (PLA) polymeric matrix. The optimization of tea waste extraction using a response surface methodology allowed achieving efficient yield and high phenolic content, which significantly enhanced the antioxidant properties of the resulting bioplastics. TW extract incorporation into PLA films increased UV-blocking capability, while keeping the oxygen permeability performance. Mechanical testing revealed improved ductility and toughness in TW extract-containing films compared to pure polylactide film, ascribed to the plasticizing effect of TW polyphenols. Food packaging assays showed effective moisture retention, comparable to low-density polyethylene (LDPE) plastics, antioxidant activity, and excellent bacteria barrier properties allowing the use for food packaging applications. Moreover, migration tests and detection of non-intentionally added substances (NIAS) allowed to establish the safety and regulatory compliance of these bioplastics. • Optimized tea waste extraction (TW) enhanced phenolic yield. • Incorporation of TW extract in PLA improved UV-blocking and mechanical properties. • Tea waste extract in PLA boosted antioxidant activity. • Food safety of PLA-TW films was confirmed by migration tests and GC-MS analysis.