Multilayer packaging: Advances in preparation techniques and emerging food applications

Abstract In recent years, with advantages of versatility, functionality, and convenience, multilayer food packaging has gained significant interest. As a single entity, multilayer packaging combines the benefits of each monolayer in terms of enhanced barrier properties, mechanical integrity, and functional properties. Of late, apart from conventional approaches such as coextrusion and lamination, concepts of nanotechnology have been used in the preparation of composite multilayer films with improved physical, chemical, and functional characteristics. Further, emerging techniques such as ultraviolet and cold plasma treatments have been used in manufacturing films with enhanced performance through surface modifications. This work provides an up‐to‐date review on advancements in the preparation of multilayer films for food packaging applications. This includes critical considerations in design, risk of interaction between the package and the food, mathematical modeling and simulation, potential for scale‐up, and costs involved. The impact of in‐package processing is also explained considering cases of nonthermal processing and advanced thermal processing. Importantly, challenges associated with degradability and recycling multilayer packages and associated implications on sustainability have been discussed.