Physicochemical characteristics, antioxidant capacity, bioactive compounds, and microbial stability of saffron-based functional beverage stored in glass bottles with and without secondary packaging at ambient conditions

• Saffron beverage was developed using broken saffron filaments, honey and lemon. • TSS, pH, and sugar content remained stable over 6 months of storage. • Secondary packaging minimized the crocin degradation and color loss. • Antioxidants and total phenols decreased regardless of packaging. • No microbial growth detected throughout the storage. The growing consumer demand for natural, health-promoting, and additive-free beverages has created a need for innovative functional drink formulations that retain quality over extended storage. This study aimed to develop a preservative-free saffron-based functional beverage using broken saffron filaments, honey, and lemon, and to evaluate the impact of packaging materials and treatment combinations on its quality attributes during a six-month storage period. The beverage was stored in two packaging conditions: without secondary packaging (P1) and with secondary packaging (P2) composed of corrugated fiberboard. Physico-chemical, bioactive, microbiological, and sensory properties were periodically assessed to determine product stability. The findings revealed that titratable acidity, total soluble solids, pH, water activity, sugars, picrocrocin, safranal, and microbiological parameters remained stable with no significant differences (p≥0.05) across treatments and packaging systems. However, significant (p≤0.05) differences were observed in color values, total phenolic content, crocin concentration, and antioxidant capacity, with beverages stored in P2 exhibiting better retention of these parameters than those in P1. Sensory evaluation indicated a gradual decline in overall acceptability over time, but P2-stored samples consistently maintained higher scores. Microbiological analyses confirmed product stability throughout storage, likely due to the antimicrobial effects of honey and lemon. This study highlights the effectiveness of secondary packaging in preserving the functional, sensory, and visual qualities of a saffron-based beverage and supports its potential as a clean-label product tailored to modern consumer preferences.