Evaluation of PBAT-Starch Nanoclay Composite Films for Quality Retention of Toast during Storage

Aims: This study aimed to develop and evaluate nanoclay-reinforced PBAT-starch biodegradable films for toast packaging, with a focus on quality retention and sustainability during storage. Study design: An experimental design was adopted with four film formulations: T0 (PBAT-only), T1 (PBAT:Starch 95:5), T2 (90:10), and T3 (85:15), each reinforced with 3% nanoclay. Place and Duration of Study: The research was carried out in the Department of Processing and Food Engineering, SHUATS, Prayagraj, India, over a three-month experimental period. Methodology: Films were synthesized and characterized for mechanical, chemical, microbiological, and migration properties. Toast samples were packaged in these films and stored at ambient conditions for three months. Quality parameters including moisture retention, peroxide and acid values, microbial counts, and texture were periodically evaluated. Results: In films with starch and nanoclay, all parameters showed better preservation. Over a three-month period, T3 demonstrated the best results, with lower AV (0.88 mg KOH/g fat vs. 1.16 in T0), lower PV (6.00 meq O₂/kg vs. 8.33 in T0), less microbial growth (TPC 5.9×10³ CFU/g and YMC 4.9×10² CFU/g vs. 8.1×10³ and 7.8×10² CFU/g in T0, respectively), and better texture retention (3.13 kg vs. 2.75 kg in control). Conclusion: Nanoclay-reinforced PBAT-starch films, particularly T3, demonstrated strong potential for eco-friendly packaging of baked products. Their application can contribute to extending shelf life while reducing environmental stress caused by synthetic plastics.