Utilization of orange juicing waste (OP) as a filler material within a polymer matrix can add value to this agricultural waste and reduce dependency on non-renewable resources. This study aims to study the impact of OP filler's physical characteristics including size, loading, and retention or removal of zest on the properties of linear low density polyethylene (LLDPE) and to produce LLDPE/OP films by blown-film extrusion. LLDPE/OP sheets with zest exhibited decreased thermal stability, larger OP agglomerates, worsened dispersion, and darker yellower colors and can act as UV- and light-absorbers. Larger OP particles increased air bubble formation, decreased mechanical properties, worsen dispersion, and produced darker yellower composites. Higher OP loadings resulted in LLDPE/OP composite sheets that have darker yellower color, decreased mechanical properties, and increased the size of OP agglomerates, as well as improved distribution and worsened dispersion. LLDPE/OP sheets that had properties most like neat LLDPE were sheets containing OP without zest and smaller particles sizes. This OP was used to determine maximum OP loading for LLDPE/OP films produced by blown-film extrusion. The LLDPE/OP films were subject to a sensory similarity triangle test and a comparison of package acceptance when different OP loading was used. This study found no difference in sensory qualities of bread when packaged in LLDPE/OP to neat LLDPE films. OP loading did not influence consumer perceptions of overall liking, appearance, surface roughness, color, or smell when LLDPE/OP films with 5 and 11.5% OP loadings were compared. This study demonstrates that OP waste can be converted and physically modified into a usable filler for plastic films for food packaging applications without altering the quality of the food product.
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