B. Shrestha, Jayeeta Mitra, Saji George
Contemporary research in food packaging is focused on developing sustainable alternatives to petroleum-based materials. Pullulan, a microbial biopolymer traditionally employed as a food additive, is harnessing interest for food packaging applications due to its exceptional film-forming ability, biodegradability, and nontoxic nature. However, there are key limitations associated with the cost of production and suboptimal physicochemical attributes (e.g., inadequate water barrier and mechanical strength) that curtail the successful industrial translation of pullulan as a packaging polymer. Accordingly, this review examines effective ways for boosting biosynthetic efficiency of pullulan production through genetic and metabolic engineering of native strains and identifies emerging strategies such as targeted chemical modifications, electrospinning, incorporation of bioactive compounds, and film casting to enhance properties of pullulan-based packaging materials. Encapsulation strategies for bioactive substances are emphasized in pullulan-based active packaging for controlled release and sustained efficacy, whereas integration with pH-responsive sensing entities enables smart packaging for real-time freshness monitoring of protein-rich foods. Further, we examined regulatory and safety frameworks, providing a perspective that bridges innovation with compliance requirements for commercial deployment. All in all, this review demonstrates the potential to reduce production costs and improve film properties, which has significantly strengthened the prospects of pullulan as a sustainable, biopolymer-based alternative to synthetic materials.