Food loss and waste occur for many reasons, from crop processing to household leftovers. Even though some waste generation is unavoidable, a considerable amount is due to supply chain inefficiencies and damage during transport and handling. Packaging design and materials innovations represent real opportunities to reduce food waste within the supply chain. Besides, changes in people’s lifestyles have increased the demand for high-quality, fresh, minimally processed, and ready-to-eat food products with extended shelf-life, that need to meet strict and constantly renewed food safety regulations. In this regard, accurate monitoring of food quality and spoilage is necessary to diminish both health hazards and food waste. Thus, this work provides an overview of the most recent advances in the investigation and development of food packaging materials and design with the aim to improve food chain sustainability. Enhanced barrier and surface properties as well as active materials for food conservation are reviewed. Likewise, the function, importance, current availability, and future trends of intelligent and smart packaging systems are presented, especially considering biobased sensor development by 3D printing technology. In addition, driving factors affecting fully biobased packaging design and materials development and production are discussed, considering byproducts and waste minimization and revalorization, recyclability, biodegradability, and other possible ends-of-life and their impact on product/package system sustainability.

In this work, films containing AgNPs were obtained by different green synthesis techniques (AgNP in situ and AgNP L). The inclusion of nanoparticles in the starch matrix improved both mechanical and barrier properties. The migration of AgNPs from the nanocomposite material to three food simulants (water, 3% v/v acetic acid and 15% v/v ethanol) was studied. The experimental data were fitted by using different widely accepted mathematical models (Fickian, Ritger and Peppas, and Weibull), indicating that the AgNP migration followed a complex mechanism. The silver concentration (mg Ag per kg of simulant) that was released from the nanocomposite films was higher for the samples with AgNPs in situ than for those containing AgNP L. Likewise, the maximum release value (0.141 mg/dm² for AgNPs in situ in acetic acid simulant) was lower than the limits proposed by the legislation (European Commission and MERCOSUR; 10 and 8 mg/dm², respectively). The replacement of conventional plastic materials by biodegradable ones requires the evaluation of bio-disintegration tests in soil. In this sense, a period of 90 days was necessary to obtain ≥50% weight loss in both nanocomposite films. Additionally, the bio-disintegration of the samples did not contribute with phytotoxic compounds to the soil, allowing the germination of fast-growing seeds.

This work reviews the strategic valorization of industrial by-products as sustainable sources of biopolymers and bioactive compounds, promoting a circular economy through the efficient use of renewable resources and reducing waste generation. These strategies contribute to lowering the carbon footprint of conventional packaging and plasticulture while supporting more resilient and diverse agriculture systems. Special emphasis is placed on processing roots and tubers as renewable raw materials for the production of biodegradable films for agronomic applications as eco-friendly alternatives to petroleum-based plastics and contributing to soil and ecosystem protection. Additionally, the incorporation of by-products from yerba mate (Ilex paraguariensis) demonstrate significant potential as both matrix-forming and filler materials in biodegradable composites while also providing antioxidant activity and pH-sensing capacity. This sustainable framework is further expanded through the utilization of non-traditional species like rosehip (Rosa rubiginosa), Aloe vera (Aloe barbadensis), and topinambur (Helianthus tuberosus), which provide versatile functional matrices and bioactive compounds. Finally, the development of active and intelligent food packaging is addressed. Extracting natural pH-sensitive pigments from red cabbage and topinambur flowers enables the formulation of eco-friendly inks for real-time freshness monitoring. Ultimately, integrating these waste streams drives technological disruption, scaling sustainable, tailored solutions for global industry needs.