Functional multilayer films with nanocellulose core and plastic outer layers for high-performance oxygen and water vapor barrier food packaging
| Authors: | Yufei Nan, Daniel J. Franke, Cody Schilling, Ronald C. Sabo, Nicole M. Stark, Laurent M. Matuana |
| Year: | 2026 |
| Type: | Scientific Journal |
| Station: | Forest Products Laboratory |
| DOI: | https://doi.org/10.1016/j.tifs.2026.105750 |
| Source: | Trends in Food Science & Technology |
Abstract
Background
The increasing demand for sustainable, high-performance packaging has driven interest in multilayer films combining a cellulose nanomaterial (CNM) core layer with plastic outer layers. In these designs, the polar CNM core layer provides effective oxygen barrier properties, while non-polar plastics serve as protective layers against water vapor. This complementary structure enables improved recyclability and supports the development of circular packaging solutions.
Scope and approach
This review overview recent advances in preparation strategies, material interactions, and performance optimization of CNM-plastic multilayer films for packaging. Fabrication techniques, particularly lamination methods such as hot-roll, hot-pressing/thermo-compression, and extrusion, along with various coating methods, are reviewed regarding barrier performance, industrial scalability and recycling implications. Although such technologies are well established in traditional multi-plastic multilayer films, their transferability and limitations in CNM–plastic multilayer architectures have not been systematically analyzed. Moreover, the influence of CNM types, plastic substrates, and tie-layer adhesives on oxygen and water vapor permeability are discussed, particularly under high relative humidity, a known limitation of CNM single films.
Key findings and conclusions
This multilayer film provides excellent oxygen barrier and water vapor even at high humidity. Importantly, CNM core and plastic outer layers can be separated at lab scale by soaking in water, supporting recyclability and material reuse. Finally, challenges related to moisture sensitivity, scalability and standardization are identified, offering insights and recommendations for future research and commercial development. A deeper understanding of moisture equilibrium in interior CNM layers between water vapor barriers and interlayer adhesion is needed.