Biopolymer Paperboard Impregnation Based on Chitosan and Nanocellulose with Addition of Caffeine and Gallic Acid

In this study, the preparation and detailed characterization of a chitosan (CHT) impregnation system modified with cellulose nanofibrils (CNFs) and enriched with bioactive compounds—caffeine (CAF) and gallic acid (GA)—applied to the surface of unbleached paperboard were described. Their mechanical properties (tensile strength, elongation at break, and bursting strength), structural features, and surface barrier parameters (water absorption) were evaluated. The antibacterial activity of the formulations comprising 1% chitosan (1% CHT), 1% chitosan with 1% caffeine (1% CHT/1% CAF), and 1% chitosan with 1% gallic acid (1% CHT/1% GA)—applied to enhance the functionality of the coated paperboard—was additionally assessed. The incorporation of cellulose nanofibrils into the coating matrix markedly improved the mechanical performance of the paperboard, particularly in terms of puncture resistance and elongation at break, while all modified coatings retained high burst strength. Impregnations containing gallic acid or caffeine showed similar mechanical characteristics but improved flexibility without compromising structural integrity. Chitosan solutions containing gallic acid and solutions containing caffeine exhibited activity against the tested Gram-positive (S. aureus, L. monocytogenes) and Gram-negative (E. coli, P. aeruginosa) bacterial strains. Antibacterial analysis showed moderate activity against Gram-positive strains and strong inhibition of Gram-negative bacteria, with the 1% CHT/1% GA impregnation giving the largest zone of growth inhibition around the sample—19 mm in the agar diffusion test—indicating the strongest suppression of E. coli. It was found that incorporation of nanocellulose into the chitosan matrix significantly reduces water uptake by treated paperboard surface, which is critical in the context of food packaging. The best result—Cobb60 value of 32.85 g/m2—was achieved for the 1% CHT/1% CNF formulation, corresponding to an 87% reduction in water absorption compared to the uncoated control. The results obtained in this study indicate a promising potential for the use of these impregnation systems in sustainable packaging applications.