Development of quaternary nanocomposites made up of cassava starch, cocoa butter, lemongrass essential oil nanoemulsion, and brewery spent grain fibers

We report on production of novel quaternary nanocomposite films based on thermoplastic starch (TPS, 8% w/v) derived from cassava, cocoa butter, (CB, 30% wt.%), and lemongrass essential oil (LEO, 1:1) nanoemulsions reinforced with different concentrations of brewery spent grain (BSG, 5 or 10 wt.%) fibers, by continuous casting. The chemical composition, the morphological, thermal, mechanical properties, film barrier, biodegradability in the vegetable compound, in addition to the application in chocolates, have been widely studied. The addition of CB, LEO, and BSG caused relevant changes in the starch‐based films, such as increased extensibility (from 2.4‐BSG5 to 9.4%‐BSG10) and improved barrier to moisture (2.9 and 2.4 g.mm.kPa−1.h−1.m−2). Contrastingly, the thermal stability of the starch film was slightly decreased. The biodegradability of the herein developed quaternary nanocomposite films was the same as that of TPS films, eliminating concerns on the supplementation with active ingredients that are expected to have some biocidal effect. Despite checking antimicrobial activity only by contact under the biocomposites, chocolates packed with the films were well accepted by consumers, especially the samples of white chocolate stored in the BSG5 biocomposite. Overall, this new approach towards quaternary active, biodegradable films produced in a pilot‐scale lamination unit was successful in either improving or at least maintaining the essential properties of TPS‐based films for food packaging applications, while providing them with unique features and functionalities. Practical Application This contribution relates to new approach toward quaternary films produced in a pilot‐scale lamination unit. It relates to sustainability as it is both biodegradable and based on plant biomass, as well as produced via a clean, through high‐yield process. The four components of the edible films we developed provide it with good in properties performance, as both a passive barrier (i.e. purely physical), and active, related to the sensory attributes of food, essential to be applied in food packaging. The valorization of a BSG also adds to the relevance of our contribution within the circular bioeconomy framework.