Effects of various packaging materials and temperature conditions on the storage stability of Zea mays L. (baby corn) powder

• Sorption isotherms of baby corn powder follow a Type II sigmoidal moisture pattern. • GAB model best fits 30–40 °C data; Oswin model excels at 50 °C for EMC prediction. • Aluminium packaging ensures optimal stability by limiting moisture and microbes. • Study highlight’s role of temp-specific modeling and packaging in quality retention. This study examined the moisture sorption isotherms, storage stability, and techno functional properties of baby corn powder at 30°, 40° and 50 °C. The sorption isotherms displayed a Type II pattern with distinct bending points, revealing temperature-dependent moisture retention. At a water activity of 0.21, the equilibrium moisture content (EMC) decreased from 23.25 % at 30 °C to 15.41 % at 40 °C and 9.80 % at 50 °C. The GAB model best fit the isotherms at 30 °C and 40 °C, whereas the Oswin model performed better at 50 °C. Storage analysis highlighted aluminum (AL) packaging as the most effective at minimizing moisture absorption and color changes, while LDPE packaging presented the highest moisture content over time. All packaging types demonstrated an increase in moisture content under accelerated storage conditions, but microbial safety remained intact, with total plate count (TPC) values within safe limits. AL packaging was most effective at limiting microbial growth, especially at 50 °C with 80–90 % relative humidity. In terms of physical properties, the bulk density increased due to moisture uptake, whereas the true density decreased over time. Technological properties, including foaming capacity and emulsifying stability, are better preserved in AL packaging, with LDPE and PP experiencing greater degradation. These findings highlight the critical role of optimized storage environments and packaging materials in preserving the quality and functionality of baby corn powder.