Safe and sustainable by design-compliant LDPE food packaging embedding multicomponent nanomaterials for food protection

In response to the significant global crop losses caused by insect pests, which affect up to 40% of crops annually, there is an urgent need for safer food protection methods. This study addresses this need by proactively developing a safe and sustainable by design (SSbD) alternative to synthetic pesticides. Guided by the EC-JRC SSbD framework, the research focuses on an advanced low density polyethylene (LDPE) film embedding a multicomponent nanomaterial (MCNM), consisting of bentonite nanoclays and clove essential oil (BNT–CEO), designed to repel beetles. In detail, a three-step premarket safe-by-design assessment was performed. The first step was the safety assessment of the BNT–CEO material through i) physicochemical characterization, ii) screening for potential hazards of chemical precursors, and iii) preliminary in vitro toxicity tests. Afterwards, worker safety during both BNT–CEO synthesis and LDPE(BNT–CEO) production was assessed, analyzing dust generation and workers' potential exposure through an industrial hygiene survey followed by occupational monitoring. Lastly, consumers' safety was covered assessing the LDPE(BNT–CEO) film degradation and potential for migration of chemicals, by comparing pristine and accelerated-aged samples. Compliance with EU Regulation 10/2011 was verified by analyzing the migration of substances into food simulants. The integration of these safety evaluations early in the design process of BNT–CEO and LDPE(BNT–CEO) allowed confirmation of the material's compliance with regulatory limits and contributed to the validation of the assessment procedure as proposed by the SSbD framework. The approach here applied demonstrates how to successfully balance effective pest protection with minimal impact on consumers and workers, paving the way for the development of safer and sustainable food packaging solutions.