Preparation of multi-barrier and multi-functional paper-based materials by chitosan, ethyl cellulose and green walnut husk biorefinery products for sustainable food packaging.

The growing interest in paper-based materials for packaging is driven by their renewable and eco-friendly characteristics. However, their poor barrier performance against water, oil, and gas limits their application in the food packaging industry. In this study, we developed a simple dual-layer coating method to create water- and oil-repellent, gas barrier, antioxidant, and antibacterial paper-based materials using naturally-derived materials, including chitosan (CS), ethyl cellulose (EC), and cascade biorefinery products from green walnut husk (GWHE and CNC). The bottom CS/CNC oil-resistant coating and the top EC/GWHE water-resistant coating were applied to the paper surface. The synergistic effect of these coatings enhances the gas barrier and imparts functional properties to the paper. Compared to uncoated paper, the dual-layer-coated paper demonstrated a 239.1 % increase in tensile index, a higher kit rating value of 12/12, a lower Cobb 60 value of 3.21 mg/m, a 44.0 % decrease in water vapor permeability (WVP), and a 90.7 % reduction in air permeability (AP). Additionally, this coated paper exhibited good antioxidant and antibacterial properties and favorable biodegradability. This study provides novel insights into the valorization of GWH waste and presents a sustainable strategy for producing high-performance paper-based materials for food packaging applications.