Bio‐Based Strategies for Sustainable Packaging: Incorporation of Babassu Mesocarp Flour Into Poly(Lactic Acid) Films

ABSTRACT The widespread use of non‐biodegradable plastics in food packaging has raised critical environmental concerns, driving the pursuit of sustainable alternatives. Poly(Lactic Acid) (PLA), a biodegradable thermoplastic derived from renewable resources, offers a promising option; however, researchers can mitigate its inherent limitations by incorporating natural fillers. This study evaluated the influence of Babassu Mesocarp Flour (BMF), an agro‐industrial by‐product (3, 5, 8, and 10 wt%), on the properties of PLA‐based films produced via flat‐die extrusion. BMF exhibited high starch content (66.23/100 g) and the predominance of amylopectin over amylose. The aerated and tapped bulk density was less than 1.0 g/mL. The study evaluated the physicochemical properties (water activity, pH, acidity, and soluble solids) and identified phenolic compounds, flavonoids, and monomeric anthocyanins in BMF. Its flow behavior was characterized by a Carr Index of 36.70% and a Hausner Ratio of 1.58. The color parameters reflected the natural coloration of the babassu fruit. Thermal analysis revealed a maximum decomposition temperature of 317°C. Water solubility and absorption capacity increased linearly with heating, and the damaged starch content was approximately 7%. The composite films revealed a uniform distribution and dispersion of the starch granules, a moisture content of less than 1.3%, high water resistance (< 0.25%), maximum water vapor permeability of 0.048 g.mm/Pa.h.m 2 , maximum tear resistance of ~1.2 N, and visible light transmittance of less than 40%. The BMF content significantly affected the films' color and gloss parameters. This approach values residual biomass and promotes eco‐friendly film development in line with circular economy principles.