Development of Tailored Composite Biopolymer Film Formulations Using Minimally Refined Chitosan from American Lobster (Homarus americanus) Shell Waste for Different Food Packaging Applications

The need for sustainable alternatives to petroleum-based plastic packaging has prompted interest in biodegradable biopolymer films. This study developed edible composite films using minimally refined chitosan from American lobster (<i>Homarus americanus</i>) shell waste combined with fish gelatin, glycerol, and sunflower oil. A Box-Behnken design within a response surface methodology (RSM) framework was used to investigate the effects of these formulation variables on ten key film properties, including mechanical strength, water sensitivity, barrier performance, and optical characteristics. High-quality empirical models (R² ≥ 0.88) captured nonlinear, synergistic, and antagonistic interactions among the components, revealing trade-offs between competing attributes. Simultaneous multi-response optimization identified balanced formulations suited to various food packaging needs, including perishable, fresh, and dry products. Experimental validation of selected formulations confirmed model predictions within 5% error under laboratory conditions. Up to 68% of the inhibition activity against <i>Escherichia coli</i> was retained in a few composite formulations when compared with neat chitosan films, thus supporting their potential for active packaging. The key highlight of the present work is the use of crude chitosan derived from lobster shell waste, a low-cost, sustainable alternative to highly purified commercial sources, demonstrating the practical viability of marine byproduct valorization. Overall, this study advances the development of high-performance, application-specific biopolymer films and highlights RSM as an effective tool for optimizing multifunctional edible packaging materials. Future work should focus on enhancing antimicrobial functionality, evaluating real-world performance, and assessing consumer acceptance to support industrial adoption.