Balancing Functionality and Safety in Food Packaging Coatings

Functional coatings for food packaging offer innovative approaches to extend shelf life, preserve quality and introduce active properties such as antimicrobial or antioxidant effects. These coatings include natural bio-based films (e.g., polysaccharide or protein-based) and synthetic polymers enhanced with additives or nanomaterials. Despite their advantages (e.g., improved barrier properties, spoilage inhibition, or intelligent sensing) they also pose safety concerns. Migration of chemical constituents and additives into food can lead to toxicological risks, such as cytotoxicity or endocrine disruption. Non-intentionally added substances (NIASs) and nano-sized components further complicate safety assessments. This review outlines the main types of functional coatings, their active mechanisms, and associated safety issues. Particular focus is placed on migration phenomena, chemical interactions and health risks from common migrants including plasticizers, monomers, nanoparticles and essential oils. The EU Packaging and Packaging Waste Regulation (Regulation (EU) 2025/40), adopted in December 2024 and published in the Official Journal in January 2025, introduces comprehensive sustainability and substance-restriction requirements, including strict criteria for food packaging materials that will apply from 12 August 2026. Emerging challenges include the assessment of bio-based and recycled coatings and the toxicology of nanomaterials. Balancing functionality with safety remains crucial for next-generation, sustainable and health-compliant food packaging.