Recent Advances in Cushioning Materials for Postharvest Application: Material Sources, Fabrication Techniques, and Mitigation of Mechanical Damage

Mechanical damage caused by vibration, impact, and compression during postharvest handling, transportation, and distribution is one of the main factors leading to losses and quality deterioration of fruits and vegetables. Cushioning packaging has therefore become an effective strategy for mitigating mechanical damage and maintaining produce quality. However, most conventional cushioning materials are petroleum-based plastics. With increasing environmental pollution and growing demands for sustainable development, the development of renewable and potentially lower-impact cushioning packaging materials has become an important research focus. This review provides an overview of recent advances in cushioning materials for fruit and vegetable transportation. The physiological and biochemical changes and associated quality deterioration of fruits and vegetables under mechanical stress are analyzed, including bruising, firmness loss, water loss, metabolic disturbance, changes in bioactive compounds, and decay development. The effectiveness of different cushioning systems in mitigating mechanical damage and maintaining postharvest quality is also discussed. The major raw materials used in cushioning packaging are classified according to their plant-based, animal-based, synthetic, and inorganic origins, and their functional properties and roles within material systems are summarized. In addition, the main fabrication methods are compared in terms of structure formation, mechanical performance, advantages, limitations, processing requirements, and industrial feasibility. Current challenges related to production cost, scalability, humidity sensitivity, food-contact safety, recyclability, regulatory requirements, and life cycle sustainability are further considered. This review provides a theoretical basis and practical reference for the future development and customized design of cushioning packaging materials with improved performance.