Plant-based food waste-derived active and intelligent food packaging: integrated bioprocesses, advanced manufacturing, and circular sustainability.

Industrialized global food production generates large volumes of organic waste, particularly plant-based byproducts such as coffee grounds, okara, and tea residue. These materials are often undervalued despite containing high concentrations of cellulose, proteins, and polyphenols. Transforming these byproducts into biodegradable, bio-based packaging materials can aid the green transformation of the food industry by shifting from a linear disposal model to a circular bioeconomy while reducing environmental impact and reliance on fossil-based plastics. In this review, we evaluated systematic methodologies for the extraction of nanocellulose, proteins, and polyphenols from diverse food waste streams. This review highlights the synergy between electrospinning and 3D printing as an integrated fabrication platform and how these technologies enable the production of complex architectures, including high-surface-area nanofibrous membranes and structurally engineered matrices. Furthermore, we have investigated the functionalization of these materials via the inclusion of antioxidant and antibacterial agents, along with the integration of pH-responsive indicators for the real-time monitoring of freshness. The integration of active and intelligent functions effectively extends the shelf life of oily products, meats, seafood, and fresh produce. Advanced fabrication techniques enable precise control over the release of bioactive compounds and the sensitivity of freshness indicators. Nevertheless, despite these advancements, considerable challenges, including the inherent variability in feedstock composition, significant hurdles in industrial scalability, inferior performance in key barrier properties compared to synthetic polymers, and a fragmented regulatory landscape for bio-based food contact materials. This review distinguishes itself by providing a systematic comparison of the three focal feedstocks across the entire value chain, with particular emphasis on the synergistic integration of electrospinning and 3D printing technologies. Future research should prioritize a holistic design framework that allows multifunctional performance while maintaining full lifecycle circularity as a core principle.