Development of antioxidant-rich edible active films and coatings incorporated with de-oiled ethanolic green algae extract: a candidate for prolonging the shelf life of fresh produce

The concept of sustainability and the substitution of non-biodegradable packaging using biodegradable packaging has attracted gigantic interest. The objective of the present study was to revalorize the biowaste “de-oiled green algae biomass (DAB)” of Dunaliella tertiolecta using a green approach and the development of biodegradable chitosan (CS)-based edible active biocomposite films and coatings for prolonging the shelf life of fresh produce. Ultrasound-assisted green extraction was conducted using food-grade solvent ethanol for obtaining the bio-actives, namely “crude algae ethanolic extract (CAEE)” from DAB. The edible films (CS/CAEE) and coating solutions were developed by incorporating CAEE with varying concentrations (0 to 28%). The CAEE was subjected to MALDI-TOF-MS, NMR, and other biochemical analyses, and was found to be rich in DPPH antioxidant activity (∼40%). The CS/CAEE films were fabricated using a solvent casting method and characterized by several biochemical and physicochemical (FESEM, TGA, FTIR, XRD, WVP, UTM, and rheological) characterization techniques. The addition of CAEE into the CS matrix reduced the maximum film transparency (∼20%), water vapor permeability (∼60%); improved the crystallinity (∼24%), tensile strength (∼25%), and antioxidant activity (∼27%); and exhibited UV-Vis blocking properties as compared to the control film. Besides, the developed coating solutions and CAEE showed biocompatibility with BHK-21 fibroblast cells and antimicrobial activity against common food pathogens. The developed coating solution was applied on green chilli using a dipping method and stored at ambient temperature (25 ± 2 °C, 50–70 % RH) for 10 days. The shelf life of chillies was extended without altering the quality as compared to uncoated green chillies. Therefore, the formulated coating could be applicable for prolonging the shelf life of fresh produce.