Data-informed design of active biodegradable packaging for mangoes: Modelling, microperforation, and shelf life performance

This study proposed a reverse-engineering approach using a mathematical model to predict the number of microperforations needed for modified atmosphere packaging (MAP) design for ‘Nam Dok Mai Si Thong’ mangoes packaged in polybutylene succinate (PBS) incorporated with 1 % (w/w) lignin nanoparticles (LNPs) and 10 % (w/w) thymol (PBS + 1LNPs + 10 T). The model was used to determine the optimum number of microperforations for achieving the desired equilibrium modified atmosphere (EMA) for mango (5 % O₂ and 15 % CO₂) within O₂ (2.5 %) and CO₂ (20 %) tolerance limits. In the first experiment, respiration rate (RR) values obtained from a closed system along with predetermined data (e.g. produce weight, package area, temperature) were used to predict the number of microperforations required to achieve the desired EMA. Packaging films with 25 microperforations established the desired EMA. Results confirmed that 25 microperforations maintained the best quality throughout 35 days of storage at 12 ± 2 °C. The model was further verified using RR values from real experimental data obtained through a permeable system in the first experiment. An additional 7 and 15 microperforations were introduced to further investigate the effects of microperforations on EMA. Results confirmed that 25 microperforations achieved the desired EMA. The films with 15 and 7 microperforations reduced O₂ level to 4 % and elevated CO₂ to 18 and 20 %, respectively. Integrating MAP design with antifungal packaging highlights the benefits of combining enhanced functional materials with predictive modeling, as active packaging alone is often insufficient for extending the shelf life of fresh produce.