Industrial Scaling and Commercialization of Biopolymer-Based Food Packaging: Processing, Performance, Regulatory and Sustainability Challenges

Bio-based origin, biodegradability, and compostability represent distinct concepts, and promising laboratory results do not always translate biopolymer-based food packaging into industrial implementation. This review adopts a value-chain perspective to critically assess the transition of biopolymer-based food packaging from renewable feedstocks to commercial products and end-of-life management. It evaluates key stages of the entire value chain, including polymer production, processing technologies, economic feasibility, regulatory requirements, environmental performance, and waste-management strategies. Major barriers to commercialization include feedstock and material variability, production and purification costs, processing limitations, performance gaps, certification challenges, and insufficient recycling or composting infrastructure. Evidence from techno-economic and life cycle assessments indicate that successful implementation depends on integrated production systems, process optimization, co-product valorization, and realistic end-of-life scenarios. Advancing biopolymer packaging therefore requires coordinated development across the entire value chain rather than isolated improvements in polymer design.