A new study has found a sustainable and scalable way to improve the durability of plant-based packaging; it’s a discovery that researchers say could help curb the environmental footprint of plastic.

In the study, researchers used advanced plasma technology to apply layered, protective coatings to the surface of cellulosic nanofibril (CNF) films, with the goal of reducing water absorption and improving moisture resistance.

They found that one of the plasma-treated coatings reduced liquid water absorption in CNF films to less than 1%, while another weakened the film’s moisture barrier and allowed more water vapor to pass through.

According to the researchers, the results show that the plasma technology — dielectric barrier discharge (DBD) plasma — can be used to precisely control how CNF films interact with moisture, opening new possibilities for plant-based packaging. 

“This research provides a practical strategy for turning natural plant and tree fibers into functional, water-resistant packaging. It moves society one step closer to replacing everyday plastic wraps with truly renewable, biodegradable materials,” said one of the study’s lead authors Nathalie Lavoine, an associate professor in the Department of Forest Biomaterials at North Carolina State University. 

CNF films are derived from renewable biomass such as wood pulp. They are completely biodegradable and provide strong barriers against oxygen and grease, offering a more sustainable alternative for additives, coatings and films in packaging products.

Many conventional packaging products such as potato chip bags, candy wrappers and squeeze pouches are made by fusing multiple layers of petroleum-based plastics with materials like aluminum foil or paper. 

Because the layers are difficult to separate, standard recycling facilities often cannot process this type of packaging. As a result, it may end up in landfills, where it can eventually break down into microplastics that can contaminate soil and water.

Widespread industrial adoption of more sustainable alternatives like CNF films remains limited in part because of their poor moisture barrier performance. Because cellulose naturally attracts water, the films rapidly absorb moisture from the environment. 

Moisture absorption can compromise the structural integrity of CNF films, causing them to lose strength and experience a significant reduction in gas barrier performance. In packaging, this can compromise product protection and shorten shelf life.

If CNF films were used in a potato chip bag and that bag were exposed to high humidity, for example, moisture could permeate the film and reach the chips. This could cause the chips to lose their crispness and become stale. For some foods, moisture can promote the development of bacteria, resulting in foodborne illness.

Plasma treatment helps address these problems by modifying the surface of CNF films to block water, while preserving the original mechanical performance and structural integrity of the cellulose. 

Lavoine said one of the primary advantages of plasma treatment is that the technology itself is more sustainable than traditional chemical coating processes that use large amounts of water, generate high heat and produce toxic waste.

The technology is also scalable, according to Lavoine. In fact, the technology is already used in the packaging industry, meaning the DBD plasma treatment process can be seamlessly integrated into existing manufacturing lines.

Still, Lavoine said that she and her collaborators must address several key challenges before DBD plasma treatment can reach real-world production. That includes refining the process so that it doesn’t allow water vapor to leak through.

While that permeability can be useful for tailoring CNF films for medical products such as breathable wound dressings, it would need to be minimized for packaging applications where moisture resistance is essential.

Lavoine said additional testing and optimization are also needed to assess coating speeds, energy use and physical durability, ensuring the material can withstand real-world handling while remaining economically viable and environmentally and socially safe.

The paper “Surface modification of cellulose nanofibril films via organosilicon deposition using dielectric barrier discharge plasma (DBD) plasma for packaging applications,” is published in the journal Applied Surface Science. Co-authors include Mirela A. Artner of NC State University, Lucia Švandová of Masaryk University, and Jacopo Profili of the University of Quebec in Rimouski.

This research was supported in part by the College of Natural Resources at NC State University, the 2022-23 NC State Internationalization Seed Grant, the Mitacs Globalink Research Award (#IT35099) and the intramural research program of the U.S. Department of Agriculture, National Institute of Food and Agriculture, McIntire-Stennis, grant number NI22MSCFRXXXG054. 

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Note to editors: The study abstract follows.

“Surface modification of cellulose nanofibril films via organosilicon deposition using dielectric barrier discharge plasma (DBD) plasma for packaging applications”

Authors: Mirela A. Artner and Nathalie Lavoine, NC State University; Lucia Švandová, Masaryk University; and Jacopo Profili, University of Quebec in Rimouski

Published: September 8, Applied Surface Science

DOI: 10.1016/j.apsusc.2026.168134

Abstract: Films made of cellulose nanofibrils (CNFs) are promising sustainable alternatives to petroleum-based plastic packaging due to their gas and grease barrier properties, high strength-to-flexibility ratio, tunable transparency, and biodegradability. However, cellulose’s hygroscopic nature limits its direct use in food packaging. Here, we exploit dielectric barrier discharge (DBD) plasma to tune the surface properties of CNF films and improve their water/moisture barrier performance. Two strategies were tested: (i) static-mode deposition of organosilicon fragments using 2,4,6,8-tetramethylcyclotetrasiloxane (TMCTS) as precursor, and (ii) formation of multilayers with varied surface chemistries by adjusting the plasma carrier gas and organosilicon fragment chemistry. Strategy (i) identified process parameters enabling uniform deposition of hydrophobic TMCTS fragments on CNF film surfaces. Strategy (ii) extended this by creating a multilayer structure combining tailored inorganic (hydrophilic) and organic (hydrophobic) layers, which substantially reduced water absorption and improved protection relative to untreated films. These results demonstrate that optimizing plasma gas composition, treatment time, and application mode (static vs. dynamic) allows controlled deposition of chemical moieties, enabling CNF films with tunable water and water–vapor barrier properties suited to diverse food-packaging requirements. Plasma treatment thus offers a sustainable, scalable route to enhance CNF film performance and expand their use in packaging applications.