Integrated sustainable process design framework for cassava biobased packaging materials: Critical review of current challenges, emerging trends and prospects

•Critical review on cassava biobased material, technologies and application in food industry.•Conventional methods for cassava biobased materials pose tailor-use challenges.•Potential to improve cassava biobased material functional performance and application.•SRRC system can recover all waste cassava and guarantee zero-environment footprint.•Integrated process design can foster sustainable cassava biobased packaging systems.

BackgroundCassava represents a reasonable share in biobased material development globally. The production of its biopolymer derivatives using conventional techniques/methods is accompanied by significant wastes with potential negative environmental impact. Among the biopolymer derivatives, starch dominates as lone additive in cast matrices with packaging limitations, requiring other biopolymer derivatives, and/or external-source modifiers for matrix improvement. Exploiting integrated sustainable engineering process design of all biopolymer derivatives, is a novel approach in designing efficient system of cassava biobased materials for food and non-food applications.Scope and approachA critical review on the current and emerging techniques and methodologies to address cassava wastes and challenges of cassava research for application on biobased packaging are provided. The potential of integrated sustainable engineering process design framework for packaging system is discussed, and prospects for improvement suggested.Key findings and conclusionsChallenges of significant waste generated during conventional processing and on the application process aiming at tailoring materials to industrial needs are reported. These materials should be improved using a holistic approach reflecting the target products, variable environment, minimising production costs and energy. Use of novel material resources, eliminating waste, and employing a standardised methodology via desirability optimisation, present a promising process integration tool for development of sustainable cassava biobased systems.