Protein‐Based Edible Films and Nanocomposites: A Comprehensive Review of Sources, Advanced Fabrication Strategies, and Emerging Applications in Smart Food Packaging

ABSTRACT

Growing environmental concerns surrounding conventional plastics have accelerated interest in protein‐based edible films as sustainable alternatives to petroleum‐derived food packaging materials. This article presents a critical and integrative analysis of recent advances in protein‐based edible films for food preservation, with particular emphasis on their composition, fabrication strategies, structure–property relationships and application potential. Proteins obtained from both plant and animal origins provide a diverse and renewable resource base for film development, with additional advantages arising from the valorization of agricultural, dairy, and seafood processing by‐products. A variety of fabrication techniques have been employed to produce protein‐based films, including solvent casting, extrusion, electrospinning, three‐dimensional printing, and electrohydrodynamic processing. Key performance attributes such as mechanical strength, moisture resistance, gas barrier efficiency and thermal stability are governed by molecular interactions, network density and processing conditions and are used to assess the suitability of these materials for packaging applications. Functional performance can be further tailored through the incorporation of plasticizers, cross‐linking agents, nanoparticles, and bioactive additives, enabling improvements in flexibility, durability, antimicrobial activity, and controlled release behavior. Although trade‐offs between flexibility, barrier properties and stability remain a key design challenge. Emerging approaches that integrate metal–organic frameworks offer new opportunities for the development of intelligent packaging systems capable of real‐time freshness monitoring. Despite significant progress, challenges remain in large‐scale manufacturing, standardization, regulatory compliance, and comprehensive environmental impact assessment. Consequently, a holistic evaluation that integrates material design, sustainability considerations, and consumer acceptance is essential for advancing protein‐based edible films toward practical and commercial adoption.