Biobased active materials using plant secondary metabolites: Current advances, challenges, and prospects

The depletion of natural resources has emerged as a major global concern, accelerating the transition from petroleum-based to renewable materials. The development of biobased ‘active’ materials is emerging especially in food packaging to ensure safety and functionality. Such packaging systems containing bioactive ingredients provide effective antioxidant, antimicrobial, and UV-protective features extending food shelf life. In this context, plant-derived secondary metabolites have gained substantial interest as functional reinforcements. These compounds not only provide food protection but also contribute to environmental safety owing to their inherent biocompatibility, biodegradability, and compostability. However, their high production costs remain a major challenge to large-scale applications. Therefore, the valorization of agro-food byproducts/wastes has been increasingly promoted. This review aims to discuss the combined use of plant secondary metabolites and biopolymers for the development of innovative packaging solutions, highlighting recent advances and functional performance. Furthermore, key challenges limiting their real-world applicability are addressed. In particular, the intrinsic hydrophilicity of many biobased materials compromises their moisture barrier and mechanical stability. To overcome this limitation, the use of biobased hydrophobic ingredients including natural waxes has emerged as a sustainable and effective approach to enhance water resistance while preserving the bioactive functionality of the packaging materials.