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. 2025 Jan 31;17(3):387.
doi: 10.3390/polym17030387.

Development of Zein-PEG400/PVA-Chitosan Bilayer Films for Intelligent Packaging

Rong Sun  1   2 , Liangliang Li  2 , Jiangjie Zhou  2 , Yongfeng Zhang  2 , Haiya Sun  2 , Datong Zhang  3 , Qi Wu  1
Affiliations

Development of Zein-PEG400/PVA-Chitosan Bilayer Films for Intelligent Packaging

Rong Sun et al. Polymers (Basel). .

Abstract

Zein exhibits excellent biodegradability, thermal stability, UV resistance, and water barrier properties, making it a promising candidate for food packaging applications. However, pure zein films suffer from brittleness and poor mechanical strength, which limit their practical use. In this study, a unique bilayer packaging film (ZP/P-C) was developed using a layer-by-layer solution casting technique, where hydrophobic zein was coated onto a polyvinyl alcohol and chitosan composite layer (P-C). Incorporating PEG400 into the zein layer improved the interfacial compatibility of the bilayer film, increasing its uniformity and toughness. The resulting bilayer films demonstrated enhanced mechanical properties, flexibility, and water vapor barrier performance. Specifically, the ZP7.5/P-C bilayer film showed an elongation at break of 68.74% and a modulus of elasticity of 187.19 MPa. It had a water vapor permeability of 6.60 × 10-11 g·m·m-2·s-1·Pa-1 and provided near-complete UV protection within the 200-350 nm range. Furthermore, an intelligent detection bilayer film was created by integrating anthocyanin extract into the zein layer. Adding anthocyanin improved the film's antioxidant properties and allowed it to respond colorimetrically to total volatile basic nitrogen. The bilayer film ZPBA1.0/P-C displayed an excellent antioxidant activity (45.8%) and remarkable color change (ΔE = 20.2) in response to ammonia, effectively indicating shrimp spoilage in 48 h (ΔE > 10). This investigation spotlights the potential of zein-based bilayer films in active and intelligent food packaging, offering innovative strategies to improve food safety and extend the shelf life of perishable goods.

Keywords: anthocyanin; bilayer film; intelligent packaging; zein.

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Conflict of interest statement

Author Datong Zhang was employed by the company Hangzhou Hydrotech Co., Ltd. The remaining authors declare that the research was conducted in the absence of any commercial or financial relationships that could be construed as a potential conflict of interest. The funding sponsors had no role in the design of the study; in the collection, analysis, or interpretation of data; in the writing of the manuscript, and in the decision to publish the results.

Figures

Figure 1
Figure 1
FTIR spectra of zein, PVA, CS (a) and different films (b).
Figure 2
Figure 2
Cross-section SEM images of the single-layer and bilayer films.
Figure 3
Figure 3
XRD spectra of different single-layer and bilayer films.
Figure 4
Figure 4
Contact angle of the different films.
Figure 5
Figure 5
Water vapor permeability of the films.
Figure 6
Figure 6
(a) Light transmittance and haze of the films; (b) UV-vis spectra of the films.
Figure 7
Figure 7
Antioxidant activity of the films.
Figure 8
Figure 8
Color change in the films under different exposure time of NH3 vapor.
Figure 9
Figure 9
The color difference value of the films.
Figure 10
Figure 10
(a) Color changes in shrimp with ZPBA0/P-C and ZPBA1.0/P-C bilayer films at storage intervals of 0 h, 12 h, 24 h, and 48 h; (b) The ΔE and TVBN values of ZPBA0/P-C and ZPBA1.0/P-C films during the storage period for packaged shrimp. The solid line represents ΔE, and the dashed line represents TVBN.
See this image and copyright information in PMC

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