Eco-friendly Poly(butylene adipate-co-butylene terephthalate) / Poly(lactic acid) packaging films with grape seed extract for extending the shelf life of strawberries and broccoli

In pursuit of sustainable food packaging, biodegradable composite films based on poly(butylene adipate-co-butylene terephthalate) (PBAT) and poly(lactic acid) (PLA) were developed via melt compounding and blown film extrusion, incorporating grape seed extract (GSE) as a natural antioxidant. The effects of GSE on film morphology, mechanical properties, antioxidant activity, barrier performance, food contact safety, and compost disintegration were systematically investigated. Comprehensive antioxidant assessments using DPPH (methanol and water phases) and ABTS assays confirmed potent radical scavenging activity, with over 90% activity observed in films containing 1% GSE. Quantitative GSE release studies revealed concentration-dependent migration behavior, while 95% ethanol migration tests demonstrated that the films are unsuitable for lipid-rich foods. Films with 0.6% GSE showed optimal mechanical performance, low moisture uptake, and favorable UV shielding. Packaging trials with strawberries and broccoli revealed significant shelf-life extension compared to commercial polyethylene films, confirming the films’ suitability for high-respiration fresh produce. Furthermore, all films achieved over 90% biodegradation after 240 days under composting conditions. These findings demonstrate that PBAT/PLA/GSE films offer a promising biodegradable solution for active packaging of fresh fruits and vegetables. • Biodegradable PBAT/PLA films were successfully fabricated using blown film extrusion incorporating grape seed extract (GSE) as a natural antioxidant. • Multiple antioxidant assays (DPPH, ABTS) in both methanol and aqueous phases confirmed strong radical scavenging activity of GSE-containing films. • UV–Vis spectrophotometry was used to quantify GSE release, revealing concentration- and time-dependent migration profiles. • 95% ethanol migration tests demonstrated that the films are not suitable for fatty foods due to excessive migration, defining their safe application scope. • Shelf-life studies with strawberries and broccoli showed significant preservation effects, especially with 1% GSE films. • All films achieved >90% disintegration after 240 days under composting conditions, confirming their environmental compatibility.