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Innovative plasma-polymerized bilayer coating featuring a citronellal-based antimicrobial layer and a
Maryam Zabihzadeh Khajavi1, Anton Nikiforov2, Rino Morent3
1Ghent University, Department of Food Technology, Safety and Health, Research Unit Food Microbiology and Food Preservation (FMFP), Belgium; Ghent University, Department of Applied Physics, Research Unit Plasma Technology (RUPT), Belgium.
Food Research International (Ottawa, Ont.)
|May 22, 2026
Summary
Active food packaging with controlled antimicrobial release was developed using a plasma-polymerized bilayer coating on polylactic acid (PLA). This system effectively controlled citronellal release, enhancing food safety and shelf life.
Area of Science:
- Materials Science
- Food Science
- Polymer Science
Background:
- Active food packaging is crucial for enhancing food safety and extending shelf life.
- Controlled release of antimicrobial agents is key to effective active packaging.
- Plasma polymerization offers a versatile method for creating functional coatings.
Purpose of the Study:
- To develop a plasma-polymerized bilayer coating on polylactic acid (PLA) for controlled antimicrobial release.
- To investigate the effect of a polycaprolactone (PCL) barrier layer on citronellal release kinetics.
- To evaluate the antimicrobial efficacy of the developed active packaging system against foodborne pathogens.
Main Methods:
- Fabrication of a bilayer coating comprising a citronellal-based layer and a PCL barrier layer on PLA using plasma polymerization.
- Surface characterization to confirm coating integrity and functionality.
- In vitro release studies using 95% ethanol to quantify citronellal release over time.
- Antimicrobial efficacy tests on vacuum-packed pork sausage against Listeria monocytogenes and lactic acid bacteria.
Main Results:
- The bilayer coating significantly reduced and controlled citronellal release compared to a pristine coating, with release decreasing substantially with increasing PCL thickness.
- The 30 nm PCL layer demonstrated an optimal balance between release rate and sustained antimicrobial activity.
- Bilayer coatings provided prolonged antimicrobial activity against Listeria monocytogenes and lactic acid bacteria over 11 days, unlike the initial burst and subsequent depletion seen with the pristine coating.
Conclusions:
- The developed plasma-polymerized bilayer coating effectively modulates citronellal release, enabling sustained antimicrobial activity.
- The polycaprolactone barrier layer is crucial for controlling the release rate of the antimicrobial agent.
- This active packaging system shows significant promise for improving food safety and extending the shelf life of perishable food products.
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