A novel non-iron-based starch, lignin, and halloysite-based oxygen scavenging composite for food packaging applications

Abstract

Active packaging technologies are essential for maintaining food quality by reducing oxidative degradation. While iron-based oxygen scavengers are common, concerns regarding safety and sustainability have moved the focus toward bio-based alternatives. In this study, a novel, physically blended bio-based oxygen scavenging system of starch, lignin, halloysite nanoclay (HNC), and calcium carbonate (CaCO₃) was developed. The composite was prepared by pre-loading HNC with CaCO₃, followed by blending with lignin at varying mass ratios (1 : 0 to 5 : 1) and a constant starch concentration. The incorporation of CaCO₃ and HNC was used to overcome the inherent diffusion limitations of dense lignin–starch matrices by creating a more interconnected porous network. The oxygen scavenging potential of the composite was evaluated at three storage temperatures (5 °C, 25 °C, and 60 °C) over 30 days. The results showed clear temperature-dependent behavior; the system was found to be dormant at 5 °C, providing a controlled-activation profile ideal for cold-chain logistics, while exhibiting accelerated kinetics at higher temperatures. Among the formulations, L4H1 demonstrated the highest oxygen-scavenging efficiency, achieving capacities of 7.13 mL O₂ per g at 25 °C and 19.40 mL O₂ per g at 60 °C. Kinetic modeling confirmed zero-order O₂ absorption governed by phenolic site availability, while Arrhenius analysis revealed diffusion-controlled temperature sensitivity. These findings demonstrate the potential of the developed material as an alternative to conventional metallic oxygen scavenger sachets for shelf-stable food packaging applications.