Ultrasound-assisted water based sustainable extraction of potato peel extract for the development of potato starch based active edible films for the preservation of fresh-cut potatoes

The increasing production of plastic packaging waste, combined with the limited shelf life of fresh-cut produce, has intensified the demand for sustainable packaging options that can also enhance food preservation. This study formulated biodegradable active films using potato starch (PS) and enriched them with potato peel extract (PPE) via sustainable ultrasonic-assisted extraction (UAE) with water (pulsed mode: 5 s on/5 s off; 300 W; 30 kHz; 25 min; 45 °C). PPE was incorporated into PS films at concentrations of 2–10% (w/w), and the resulting films were examined for, mechanical, physical, optical, barrier, antioxidant as well as antimicrobial properties. SEM analysis demonstrated smoother, more compact surfaces with higher PPE content, while FTIR confirmed enhanced hydrogen bonding without altering the starch backbone. Thickness of the film increased from 0.01 ± 0.01 mm (T 0 ) to 0.31 ± 0.01 mm (T 5 ), whereas moisture content, water solubility, and water vapor permeability decreased significantly, indicating improved structural integrity and barrier performance. Color parameters and transparency showed dose-dependent changes due to phenolic compounds, while mechanical strength (TS and EAB) slightly decreased at higher extract concentrations. Antioxidant activity increased progressively, with TPC reaching 18.71 mg GAE/g, TFC 3.92 mg QE/ g, and DPPH scavenging 40.81%. Films exhibited dose-dependent antimicrobial activity against S. aureus (2.09–19.13 mm), E. coli (1.91–31.34 mm), and S. enterica (1.45–21.61 mm). Biodegradability tests showed complete degradation of low-extract films by 15 days, while higher PPE films degraded nearly completely, contrasting with non-degradable polyethylene controls. Application on fresh-cut potatoes demonstrated that films with higher PPE concentrations (T 4 –T 5 ) reduced visible browning and delayed spoilage-associated visual changes during 7 days of ambient storage. Overall, the results highlight the potential of using food commodity-derived starch as a packaging material and food waste (potato peel) to develop active edible biodegradable films via sustainable technologies, combining environmental benefits with enhanced preservation of fresh-cut products.