Development of zein/ethyl cellulose composite films for sausage smoking: Effects on smoke-derived volatile compounds

Smoking processes generate polycyclic aromatic hydrocarbons (PAHs), raising safety concerns in smoked meats. This study developed zein/ethyl cellulose (EC) composite films to modulate smoke compound transfer during sausage smoking while maintaining desirable aroma. Films were prepared at zein:EC ratios of 1:0, 3:1, 4:1, and 5:1 (ZE-10, ZE-31, ZE-41, ZE-51) and characterized for morphology, mechanical strength, thermal stability, and moisture resistance. EC incorporation increased film density, water resistance, and thermal stability, whereas excessive EC induced aggregation and weakened mechanical performance. GC-MS/MS analysis of smoked sausages revealed that ZE-41 preserved key smoke-derived phenols, furans, and ketones at levels comparable to the untreated control. Principal component analysis confirmed that ZE-41 exhibited selective permeability to characteristic smoke volatiles with minimal alteration of the overall volatile profile. Among the formulations, ZE-41 achieved the optimal balance between physicochemical stability and aroma retention, demonstrating potential as a functional smoking film for safer smoked sausage production.