Aim: The increasing environmental concerns regarding the use of non-biodegradable plastic packaging have driven the search for sustainable alternatives. Chitosan, a biopolymer obtained from chitin, is known for its biodegradability, biocompatibility and antimicrobial properties. Shellac, a natural resin secreted by the lac bug, is also biodegradable and widely used in food and pharmaceutical coatings. Combining these materials to create a biocomposite fabric for packaging could offer a viable eco-friendly alternative to traditional plastics. This research seeks to create and analyze a biocomposite fabric made from chitosan and shellac for use in packaging. It examines the mechanical strength, barrier effectiveness and biodegradability of the biocomposites to determine their potential as eco-friendly packaging solutions. Materials and Methods: Chitosan, obtained from chitin and commercially available shellac, a natural resin, were utilized to create biocomposite films. The process involved dissolving chitosan in acetic acid and shellac in ethanol. Mechanical properties were assessed by measuring tensile strength and elongation at break with a universal testing machine. Barrier properties were examined using Water Vapor Transmission Rate (WVTR) and water contact angle tests. Additionally, the biocomposites were characterized using FTIR, SEM and TGA analyses. Results: The biocomposite films exhibited good tensile strength and flexibility. The optimal chitosan-to-shellac ratio provided a balance between strength and flexibility, making the material suitable for packaging. The biocomposites demonstrated significant resistance to moisture and oxygen permeation, crucial for maintaining the integrity of packaged goods. The study ascertains the biocomposite formation and their thermal stability. The study successfully developed a chitosan-shellac based biocomposite fabric with promising characteristics for packaging applications. The biocomposites exhibited favorable mechanical properties, effective barrier performance and excellent thermal stability. These findings suggest that chitosan-shellac biocomposite fabrics could serve as a sustainable alternative to conventional plastic packaging, contributing to environmental conservation and sustainability efforts. Further research may explore the scalability of production and the potential for incorporating other natural additives to enhance performance
