Orodispersible films as carriers of bioactive compounds: recent advances, challenges, and potential applications in functional foods and nutraceuticals

Abstract

Orally disintegrating films (ODFs) have become one of the most promising platforms for the delivery of bioactive compounds, with consolidated technological maturity in the pharmaceutical sector, where they have reached Technology Readiness Level 9 (TRL 9). However, the food sector still underutilizes this technology, remaining largely restricted to the production of conventional edible films. Current reviews focus on production techniques and physicochemical properties, highlighting the need for an analysis directed toward real application in food systems. This review integrates formulation and processing aspects with critical dimensions for the food sector: sensory evaluation, disintegration time, release kinetics, encapsulation efficiency, biocompound stability, and consumer acceptance. The impact of natural and semisynthetic polymers (such as pullulan, carboxymethyl cellulose, maltodextrin, alginate, and gelatin) is discussed in comparison with synthetic ones (such as polyvinyl alcohol), emphasizing biocompatibility and solubility. Regarding production methods, the work covers traditional solvent casting as well as emerging technologies such as electrospinning, centrifugal spinning, and 2D/3D printing, evaluating their potential for precision nutrition. The main characterization techniques (contact angle, mechanical properties, thermal analysis, morphology, surface pH, and disintegration) are also correlated with the functional performance of ODFs. It is concluded that an integrated understanding of formulation, processing, and sensory acceptance provides the scientific foundation needed to overcome current industrial limitations, thereby guiding the development of convenient, safe, and personalized functional foods and nutraceuticals.