Journal of Advances in Food Science & Technology

Increasing environmental concerns associated with petroleum-based plastic packaging have accelerated the search for biodegradable and economically feasible alternatives for food-packaging applications. The present study evaluated the techno-economic feasibility, commercial potential, and practical packaging performance of an optimised corn starch-based bio-composite film reinforced with sunflower seed hull powder and thyme essential oil. An optimized bio-composite formulation (OBF) containing 5 g corn starch, 0.50 g sunflower seed hull powder, 2.5 mL glycerol, 3.0 mL white vinegar, 0.25 mL thyme essential oil, and 50 mL distilled water was selected for economic evaluation. The production cost was estimated under laboratory-scale conditions by considering raw-material, energy, labour, and equipment costs. The total production cost of one laboratory-scale batch, which produced a single optimized film sheet (20.7 × 15.5 cm), was estimated at ₹13.00, corresponding to a production cost of ₹406.25 m⁻². Raw materials constituted the largest share of the total production cost (approximately 77%), whereas energy, labour, and equipment accounted for the remaining manufacturing expenditure. Comparative cost analysis indicated that the developed bio-composite film had a higher production cost than conventional petroleum-based plastic films because of laboratory-scale production and manual processing. However, the use of inexpensive corn starch, sunflower seed hull powder as an agricultural by-product, and naturally derived thyme essential oil may enhance the film's environmental sustainability and commercial potential. The optimized film also demonstrated preliminary packaging feasibility, with satisfactory flexibility, structural integrity, handling characteristics, and wrapping performance during 15 days of ambient storage when used as a secondary packaging material for commercially packaged Mango Bite candies. Overall, the developed bio-composite film showed potential as a sustainable alternative to conventional plastic packaging. Nevertheless, further pilot-scale production, comprehensive performance evaluation, and industrial-scale validation are required before commercial implementation.