Development of a proactive-diagnostic smart packaging system for real-time freshness monitoring and shelf-life extension of refrigerated broiler breast.

Fresh broiler breast meat is highly susceptible to rapid microbial proliferation and lipid oxidation during refrigerated storage, necessitating advanced preservation and quality-monitoring strategies. This study developed an eco-friendly, dual-functional "proactive-diagnostic" smart packaging system by incorporating lemongrass essential oil (LEO; 0, 2.5, and 5.0% w/v) into a transglutaminase-crosslinked fish gelatin/sodium alginate active matrix, coupled with a headspace butterfly pea anthocyanin (BPA) colorimetric indicator. Results indicated that LEO incorporation significantly (p < 0.05) enhanced the functional properties of the films, notably increasing UV-shielding capacity and reduced water solubility by 26%, thereby confirming improved structural stability within high-moisture packaging environments. Mechanical analysis demonstrated a concentration-dependent plasticizing effect of LEO, which significantly improved film elongation at break while maintaining adequate tensile strength. In application trials with fresh broiler breasts stored at 4 ± 2°C, the 5.0% LEO-loaded active film exhibited superior antimicrobial and antioxidant performance, effectively suppressing Escherichia coli and Staphylococcus aureus growth. By day 7 of storage, the LEO-loaded active film maintained total volatile basic nitrogen (TVB-N) and TBARS values at 15.77 ± 0.35 mg N/100 g and 1.32 ± 0.10 mg MDA/kg, respectively, remaining well below established microbiological spoilage thresholds. Furthermore, the LEO-loaded film substantially minimized drip loss and stabilized surface redness (a*), thereby preserving myofibrillar structural integrity and visual acceptability. Concurrently, the headspace BPA indicator exhibited a distinct, non-destructive halochromic transition from dark purple to blue and green, driven by the structural transformation of anthocyanins into chalcone derivatives in response to muscle pH shifts and TVB-N accumulation. In conclusion, this 5.0% LEO-loaded smart packaging system extends the refrigerated shelf-life of broiler breast by at least 3 days and provides a reliable, non-destructive tool for real-time quality validation, offering a potential sustainable approach to reduce food waste in the poultry supply chain.