The increasing environmental burden associated with petroleum-based plastic packaging has stimulated growing interest in microalgae-derived bio-based materials for sustainable food packaging applications. In this study, active composite films based on chitosan (CS) and Chlorella vulgaris (CV) oil were prepared using a solution-casting method. Scanning electron microscopy (SEM) observations indicated that the incorporation of CV oil significantly altered the film morphology, resulting in uniformly distributed porous microstructures. Mechanical property analysis showed a gradual decrease in tensile strength, accompanied by an initial increase followed by a decline in elongation at break, with a maximum enhancement of 66%. The surface hydrophobicity of the films increased with increasing CV oil content, as evidenced by an increase in water contact angle up to 83.99°, while water solubility, swelling ratio, and water vapor permeability were correspondingly reduced. Optical measurements revealed a pronounced decrease in UV–visible light transmittance, indicating improved light-barrier performance. Furthermore, bioactive compounds present in CV oil enhanced the antioxidant and antimicrobial properties of the films, with the DPPH radical scavenging activity increasing from 43.17% to 73.45% and effective inhibition observed against Escherichia coli and Staphylococcus aureus. These results demonstrate the potential of CV oil as a functional microalgae-derived additive for the development of sustainable and bioactive packaging films.
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