Description:FIELD OF THE INVENTION
This invention relates to an eco-friendly packaging product for extending the shelf life of produce.
BACKGROUND OF THE INVENTION
Preserving freshness in the farm-to-fork supply chains of fresh fruits, vegetables and flowers has a significant impact on their quality and reduces post-harvest waste. Since these are very thermosensitive and perishable, they are prone to softening and degradation during transport and storage, resulting in massive losses. Existing packing methods are primarily made of synthetic or non-biodegradable materials, which exacerbate these concerns by not properly managing the ripening process and are not necessarily biodegradable, thus raising environmental concerns. In this scenario food industries are constantly demanding highly innovative, eco-friendly packaging solutions that would offer improved physical, mechanical and barrier properties, coupled with an urgent demand for sustainability. This is a unique opportunity to capture post-harvest agricultural wastes like sugarcane bagasse and add, in a dual-layer coating, with the health benefits of moringa. It will maintain the freshness of the produce, increase its shelf life, enhance its appearance and add more health benefits to it while being more sustainable and decreasing reliance on harmful plastics. The approach does not only serve to throw itself onto global trends in environmental responsibility but can be used generically to sustain a more sustainable and efficient supply of food.
The proposed invention not only addresses maintaining the freshness and extension of shelf life of perishable fruits, vegetables, and flowers along the supply chains, also overcomes the challenge of existing methods of packaging that are synthetic, non-degradable which results in significant resource wastage and substantial environmental pollution.
This invention deals with a new, dual-layer biopolymer coating that links the benefits of moringa-based biopolymers with cellulose nanocrystals derived from sugarcane bagasse which helps to retain freshness and prolong the shelf life of climacteric produces in an eco-friendly way.
SUMMARY OF THE INVENTION
This summary is provided to introduce a selection of concepts, in a simplified format, that are further described in the detailed description of the invention.
This summary is neither intended to identify key or essential inventive concepts of the invention and nor is it intended for determining the scope of the invention.
This invention proposes a new eco-friendly packaging solution using a dual-layer biopolymer coating that combines moringa-based biopolymers and cellulose nanocrystals from sugarcane bagasse. This packaging offers improved mechanical strength, barrier properties, and sustainability, while extending the shelf life of climacteric produce.
To further clarify advantages and features of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof, which is illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail with the accompanying drawings.

DETAILED DESCRIPTION OF THE INVENTION
The detailed description of various exemplary embodiments of the disclosure is described herein with reference to the accompanying drawings. It should be noted that the embodiments are described herein in such details as to clearly communicate the disclosure. However, the amount of details provided herein is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the scope of the present disclosure as defined by the appended claims.
It is also to be understood that various arrangements may be devised that, although not explicitly described or shown herein, embody the principles of the present disclosure. Moreover, all statements herein reciting principles, aspects, and embodiments of the present disclosure, as well as specific examples, are intended to encompass equivalents thereof.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments. As used herein, the singular forms “a",” “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises,” “comprising,” “includes” and/or “including,” when used herein, specify the presence of stated features, integers, steps, operations, elements and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components and/or groups thereof.
It should also be noted that in some alternative implementations, the functions/acts noted may occur out of the order noted in the figures. For example, two figures shown in succession may, in fact, be executed concurrently or may sometimes be executed in the reverse order, depending upon the functionality/acts involved.
In addition, the descriptions of "first", "second", “third”, and the like in the present invention are used for the purpose of description only, and are not to be construed as indicating or implying their relative importance or implicitly indicating the number of technical features indicated. Thus, features defining "first" and "second" may include at least one of the features, either explicitly or implicitly.
Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which example embodiments belong. It will be further understood that terms, e.g., those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
This invention proposes a new eco-friendly packaging solution using a dual-layer biopolymer coating that combines moringa-based biopolymers and cellulose nanocrystals from sugarcane bagasse. This packaging offers improved mechanical strength, barrier properties, and sustainability, while extending the shelf life of climacteric produce.
The packaging product consists of two layers: an inner layer and an outer layer. The following are the composition percentages for each layer:
1. Inner Layer:
o Moringa Leaf Extract (Biopolymer): 60-70%
o Water/Solvent: 30-40%
2. Outer Layer:
o Moringa Seed Extract (Biopolymer): 50-60%
o Cellulose Nanocrystals (from Sugarcane Bagasse): 40-50%
These ratios can be adjusted slightly based on the specific requirements of the produce being packaged, such as its perishability, moisture content, and shelf-life needs.
Method of Preparing the Packaging Product:
Step 1: Preparation of the Inner Layer (Moringa Leaf Biopolymer)
1. Collection and Drying:
Moringa leaves are collected and air-dried in a clean environment until they become crisp and moisture-free.
2. Pulverization:
The dried moringa leaves are finely ground into a powder.
3. Extraction of Biopolymer:
o The ground moringa leaf powder is mixed with water or any suitable solvent (ethanol or methanol) in a ratio of 1:4 (leaf powder to solvent).
o The mixture is stirred and heated at 60-80°C for 2-3 hours to facilitate biopolymer extraction.
o After heating, the mixture is filtered to remove insoluble solids, leaving behind a moringa biopolymer solution.
4. Concentration:
The biopolymer solution is concentrated by reducing the water content using low-heat evaporation or vacuum evaporation techniques until the desired thickness is achieved.
Step 2: Preparation of the Outer Layer (Moringa Seed Biopolymer and Cellulose Nanocrystals)
1. Moringa Seed Biopolymer Extraction:
o Moringa seeds are crushed and mixed with water or another suitable solvent (in a 1:5 ratio of seed to solvent).
o The mixture is stirred and heated at 70-90°C for 2-3 hours to extract the biopolymer.
o The solution is filtered, and the liquid portion containing the biopolymer is retained.
2. Isolation of Cellulose Nanocrystals from Sugarcane Bagasse:
o Sugarcane bagasse is cleaned and dried before being treated with sodium hydroxide (NaOH) at 3-5% concentration to remove lignin and hemicellulose.
o After treatment, the fibers are further processed with an acid hydrolysis (typically sulfuric acid) process to break down the cellulose into nanocrystals.
o The nanocrystals are washed and neutralized to remove any acid residue, resulting in a suspension of cellulose nanocrystals.
3. Mixing and Formulation of the Outer Layer:
o The moringa seed biopolymer extract and cellulose nanocrystal suspension are mixed in the desired ratio (typically 1:1 or 50-60% moringa biopolymer, 40-50% cellulose nanocrystals).
o The mixture is stirred vigorously until a homogeneous solution is obtained.
o Additional thickening agents or plasticizers (such as glycerol, at 1-3% of the total volume) may be added to adjust the viscosity and flexibility of the coating.
Step 3: Application of Coating
1. Coating Process:
o The inner layer is first applied to the surface of the produce by dipping, spraying, or brushing. The coating is allowed to dry naturally or through forced air drying at 40-50°C for 1-2 hours.
o Once the inner layer is dry, the outer layer (containing the moringa seed biopolymer and cellulose nanocrystals) is applied using the same method as the inner layer.
o The second layer is also air-dried or oven-dried at 40-50°C for 1-2 hours until fully set.
Step 4: Final Packaging Product
• The final product is a two-layered biodegradable, eco-friendly packaging film that can be used to wrap fruits, vegetables, and flowers to extend their shelf life, providing both barrier and health benefits.

ADVANTAGES OF THE INVENTION
Improved barrier protection: Such a bilayer design will effectively combine moringa-based biopolymers with cellulose nanocrystals to give improved barrier properties regarding the exchange of ethylene gas and moisture loss, which is very important in shelf-life extension for climacteric produce.
Antimicrobial and Antioxidant Effects: A unique feature of this sort of coating, which are not generally seen in standard coatings, is that the inclusion of moringa biopolymers brings along antimicrobial and antioxidant effects. These act synergistically to prevent spoilage and hence maintain the nutritional value of the produce.
Sustainability and Advantages:
Biodegradability: In this respect, both the moringa-based biopolymer and cellulose nanocrystals are totally biodegradable because they are renewable and of natural origin, thus exerting a minimal impact on the environment compared to synthetic, less degradable counterparts.
Health Benefits: The built-in antioxidant and antimicrobial features in moringa enhance the health benefits of the coating, increasing value beyond what a conventional packaging solution would deliver.
Cost-Effectiveness: Replacing wood with agricultural waste like sugarcane bagasse for cellulose nanocrystals not only reduces the material cost and waste but also proves to be less expensive and more environmentally friendly.
, Claims:1. An eco-friendly packaging product for extending the shelf life of climacteric produce, comprising:
• An inner layer containing moringa leaf biopolymer extract with antimicrobial and antioxidant properties, formulated with 60-70% moringa leaf extract and 30-40% water or solvent; and
• An outer layer containing moringa seed biopolymer and cellulose nanocrystals, formulated with 50-60% moringa seed biopolymer and 40-50% cellulose nanocrystals derived from sugarcane bagasse.
2. The packaging product of claim 1, wherein the inner layer is applied as the first coating on the surface of the produce, followed by the application of the outer layer, and each layer is dried naturally or with forced air at 40-50°C.
3. The packaging product of claim 1, wherein the inner layer provides antimicrobial and antioxidant benefits to the produce, preventing spoilage and maintaining freshness.
4. The packaging product of claim 1, wherein the outer layer serves as a gas and moisture barrier, minimizing ethylene gas exchange and moisture loss, thereby prolonging the shelf life of the produce.
5. The packaging product of claim 1, wherein the combination of moringa-based biopolymers and cellulose nanocrystals provides enhanced mechanical strength, gas and moisture barrier properties, antimicrobial effects, and biodegradability.
6. The packaging product of claim 1, wherein the use of cellulose nanocrystals derived from sugarcane bagasse replaces traditional synthetic materials, promoting sustainability and reducing environmental impact.
7.. The packaging product of claim 1, wherein both the inner and outer layers are fully biodegradable and made from renewable, natural resources, contributing to an environmentally friendly packaging solution.
8. The method of preparing the eco-friendly packaging product as claimed in claim 1-7, comprising the following steps:
• Step 1: Preparing the inner layer by:
o Drying and pulverizing moringa leaves;
o Extracting biopolymers from the moringa leaf powder by mixing it with water or solvent in a 1:4 ratio and heating at 60-80°C for 2-3 hours; and
o Concentrating the extract by reducing the water content through evaporation to achieve the desired consistency;
• Step 2: Preparing the outer layer by:
o Extracting biopolymers from moringa seeds by mixing the crushed seeds with water or solvent in a 1:5 ratio and heating at 70-90°C for 2-3 hours;
o Isolating cellulose nanocrystals from sugarcane bagasse through sodium hydroxide treatment at 3-5% concentration and acid hydrolysis, followed by washing and neutralization;
o Mixing the moringa seed biopolymer extract and cellulose nanocrystals in a 50-60% to 40-50% ratio to form a homogeneous solution;
• Step 3: Applying the inner layer onto the produce by dipping, spraying, or brushing, followed by drying at 40-50°C for 1-2 hours;
• Step 4: Applying the outer layer over the dried inner layer using the same method, and drying again at 40-50°C for 1-2 hours until fully set.
9. The method of claim 8, wherein the coating formulation for the outer layer may include up to 1-3% glycerol as a plasticizer to adjust the thickness and flexibility of the packaging film.
10. The method of claim 8, wherein the cellulose nanocrystals are isolated through acid hydrolysis, using sulfuric acid as a reagent to break down cellulose into nanocrystals, followed by neutralization and washing steps.