Enhanced Xylan/PVA Composite Films via Nano-ZnO Reinforcement for Sustainable Food Packaging

The development of biodegradable alternatives to petroleum-based packaging is essential for environmental sustainability. This study presents a novel approach to enhance the performance of hemicellulose-based films by fabricating xylan/polyvinyl alcohol (PVA) composites reinforced with zinc oxide nanoparticles (nano-ZnO). To address nano-ZnO agglomeration, sodium hexametaphosphate (SHMP) was utilized as a dispersant, while sorbitol improved film flexibility. The composite films were prepared via solution casting, and the effects of nano-ZnO content (0-2.5 wt%) on mechanical, thermal, and barrier properties were systematically evaluated. Results showed that at 2 wt% nano-ZnO loading, the tensile strength increased from 15.0 MPa (control) to 26.15 MPa, representing a 74% enhancement, while oxygen permeability decreased from 1.83 to 0.50 (cm³·μm)/(m²·d·kPa). Additionally, the thermal stability also improved due to hydrogen bonding and uniform nanoparticle dispersion. At this optimized loading, the hydrophobcity was also maximized, with the contact angle peaking at 74.4° and water vapor permeability decreasing by 18% (1.53·10^-6·g·h^-1·m^-1·Pa^-1). Excessive nano-ZnO loading (>2 wt%) induced particle agglomeration, generating stress concentrators that disrupted the polymer-nanoparticle interface and compromised mechanical integrity. These findings highlight the potential of nano-ZnO-modified xylan/PVA films as sustainable, high-performance alternatives to conventional packaging. The synergistic use of SHMP and nano-ZnO provides a strategy for designing eco-friendly materials with tunable properties, advancing the use of biomass in food preservation applications.