Multifunctional whey protein composite films: Material design and AI integration for next-generation food packaging

The global food industry’s reliance on petroleum-based plastics poses severe environmental and health risks, underscored by the pervasive accumulation of microplastics in ecosystems and the human body. Whey protein (WP), an abundant and biodegradable dairy byproduct, has emerged as a promising material for sustainable food packaging. This review comprehensively examines the development of whey protein-based film(WPF), with a focus on overcoming the inherent limitations, such as hydrophilicity and moisture sensitivity, through advanced modification strategies. Key advancements include multi-scale interface engineering via polymer blending and nanofiller incorporation to optimize mechanical and barrier properties; the integration of plant-derived bioactive components to impart antimicrobial and antioxidant functionalities; and the formation of nanocomposites to introduce novel optical and responsive traits. Furthermore, we objectively evaluate the frontier of intelligent packaging, where the integration of environmentally responsive WPF with artificial intelligence(AI) algorithms enables real-time food freshness monitoring and dynamic preservation control. The synergy between material science and AI is transforming WPF from passive barriers into active, intelligent platforms. This review syn thesizes these research streams to provide a foundation for the transition of WPF from laboratory innovation to practical, next-generation food packaging solutions, ultimately addressing the dual challenges of food preservation and plastic pollution.