Chitosan Enhanced Polymers for Active Packaging: Intelligent Moisture Regulation and Non-Invasive Assessment

This work presents the non-destructive assessment of polymeric composites based on synthetic matrices low-density polyethylene (LDPE) and polystyrene (PS) enhanced with chitosan (CS) biopolymer for use in active packaging systems for moisture control. Composites were prepared by incorporating CS at different contents (1, 3 and 5 phr) into LDPE and PS matrices. To evaluate the structural and thermal alterations induced by biopolymer loading, the materials were characterized using scanning electron microscopy (SEM), X-ray diffraction (XRD), and differential scanning calorimetry (DSC). The composites’ water-regulating properties—specifically, moisture absorption, retention, diffusion, and water vapor transmission rate—were quantitively tracked. Furthermore, the mechanical integrity of both dried and water-exposed systems was assessed via Shore D hardness testing. The results reveal a direct correlation between CS concentrations and enhanced hydrophilic behavior and water absorption, primarily attributed to the polar hydroxyl and amine groups within its molecular structure. The composites maintained adequate mechanical strength even after water exposure, confirming their structural stability for practical applications. This study demonstrates that the incorporation of CS into non-polar synthetic matrices significantly improves water affinity without requiring chemical compatibilizers, representing a cost-effective route to develop responsive packaging. The promise of these composites as responsive materials for real-time environmental interaction is highlighted by the successful non-destructive monitoring of their performance. This research establishes the feasibility and efficacy of non-destructive monitoring techniques in developing active packaging technologies, accelerating the progress of polymer-based systems with integrated and tunable moisture regulation capabilities.