The performance characteristics of polylactic acid (PLA) as an active food packaging film can be highly influenced by the incorporation of active agents (AAs) into PLA, and the type of processing technique. In this review, the effect of processing techniques and the addition of natural AAs on the properties related to PLA performance as a packaging material are summarized and described through a systematic analysis, giving new insights about the relation between processing techniques, types of AA, physical–mechanical properties, barriers, optical properties, compostability, controlled release, and functionalities in order to contribute to the progress made in designing antioxidant and antimicrobial PLA packaging films. The addition of AAs into PLA films affected their optical properties and influenced polymer chain reordering, modifying their thermal properties, functionality, and compostability in terms of the chemical nature of AAs. The mechanical and barrier performance of PLA was affected by the AA’s dispersion degree and crystallinity changes resulting from specific processing techniques. In addition, hydrophobicity and AA concentration also modified the barrier properties of PLA. The release kinetics of AAs from PLA were tuned, modifying diffusion coefficient of the AAs in terms of the different physical properties of the films that resulted from specific processing techniques. Several developments based on the incorporation of antimicrobial and antioxidant substances into PLA have displayed outstanding activities for food protection against microbial growth and oxidation.

Currently, reducing packaging plastic waste and food losses are concerning topics in the food packaging industry. As an alternative for these challenges, antimicrobial and antioxidant materials have been developed by incorporating active agents (AAs) into biodegradable polymers to extend the food shelf life. In this context, developing biodegradable active materials based on polylactic acid (PLA) and natural compounds are a great alternative to maintain food safety and non‐toxicity of the packaging. AAs, such as essential oils and polyphenols, have been added mainly as antimicrobial and antioxidant natural compounds in PLA packaging. In this review, current techniques used to develop active PLA packaging films were described in order to critically compare their feasibility, advantages, limitations, and relevant processing aspects. The analysis was focused on the processing conditions, such as operation variables and stages, and factors related to the AAs, such as their concentrations, weight losses during processing, and incorporation technique, among others. Recent developments of active PLA‐based monolayers and bi‐ or multilayer films were also considered. In addition, patents on inventions and technologies on active PLA‐based films for food packaging were reviewed. This review highlights that the selection of the processing technique and conditions to obtain active PLA depends on the type of the AA regarding its volatility, solubility, and thermosensitivity.

Nanotechnology is considered a highly valued technology to reduce the current environmental problem that is derived from plastic accumulation. The need to recycle and reuse packaging materials is essential to create a sustainable society towards a circular economy. However, the reprocessing of polymers leads to the deterioration of their characteristic mechanical, optical, thermal, and barrier properties due to the degradation of their polymeric chains. When recycled polymers are reinforced with nanoadditives, aforementioned properties improve and their use in the circular economy is more viable. In this review, different types of nanoadditives and recent advances in the development of recycled polymer nanocomposites reinforced with nanoadditives will be presented. In addition, there is a description of two research topics of current interest, recyclability of nanocomposites and safety for food packaging applications. Recyclability of nanocomposites requires a study that includes the nature of the polymer matrix, the type of polymer and the concentration of nanofiller, the morphology, the presence of additives, and the conditions of the thermal‐mechanical cycles. Finally, safety section is dedicated to clarify the migration process in nanoreinforced‐recycled polymers in order to assess their safety for food contact applications.