Evaluating the Fabrication Parameters and Sustainability of Recycled Cellulosic Films for Food Packaging Applications

The increasing reliance on single-use plastics, such as PET bottles, has caused significant environmental degradation and health risks. While biodegradable alternatives like liquid packaging board (LPB) offer an eco-friendly option, they still pose notable environmental impacts, particularly when laminated with polyethylene (PE) or cellulose acetate (CA). This study addresses the need for sustainable packaging materials by developing thermoplastic cellulosic films (CEL-IL), synthesized from wastepaper using microwave-assisted ionic liquid (IL) dissolution technology to replace synthetic plastic laminations. This research optimizes the CEL-IL regeneration process via controlled incubation duration and antisolvent volume to modify the resulting thermoplasticity and mechanical strength. Additionally, the study explores the role of residual IL in altering CEL-IL’s crystallinity and thermo-tolerance. Furthermore, a life cycle assessment (LCA) compares the environmental impact of the novel LPB-CEL-IL composite with traditional LPB-CA laminations. The results show that LPB-CEL-IL reduces environmental impact by 80% during manufacturing. These findings demonstrate CEL-IL's potential as a sustainable alternative to traditional packaging, supporting global efforts to reduce reliance on non-biodegradable plastics and minimize environmental impacts.