Modulating the properties of bioactive cellulose acetate electrospun films using aloe vera gel and lemongrass essential oil for sustainable active food packaging

Background and aims Transitioning towards sustainable diets and circular food systems requires bio-based packaging that preserves food quality. This study investigates electrospun bioactive films made from cellulose acetate (CA), aloe vera gel (AG), and lemongrass essential oil (EO), with a focus on how variations in composition influence film performance relevant to active food packaging. Methods Three formulations with distinct mechanical profiles (rigid, flexible, and balanced) were fabricated by electrospinning solutions of CA, AG and EO. Morphology (visual appearance, SEM), molecular interactions and structural order (FTIR, XRD), thermal behavior (DSC, TGA), barrier properties (moisture loss, solubility, swelling index, water vapor permeability), optical performance (color, light transmission, UV–visible shielding), surface wettability (contact angle), and bioactivity (DPPH and ABTS assays; antibacterial tests against representative Gram-positive and Gram-negative strains) were evaluated. Results The prepared films showed dense, compact, mat-like morphologies and were mainly amorphous in nature without any chemical degradation of CA. The flexible (AG-rich) films retained more moisture, showed lower thermal transition temperature, higher water solubility, greater swelling- induced mass loss, and higher water vapor permeability. In contrast, rigid and balance films (containing relatively higher CA and EO levels), demonstrated better dimensional stability and resistance to moisture. The optical measurements showed tunable opacity, UV–visible shielding, and wettability, while the EO-enriched balanced film exhibited the highest antioxidant capacity and broad-spectrum antibacterial activity. Conclusion Through regulating CA-AG-EO composition, it is possible to manage the mechanical, thermal, barrier, optical, and bioactive properties in electrospun films at the same time. These cellulose acetate-based, multifunctional materials are promising candidates for active food packaging and support circular and more sustainable food systems.