IoT biosensors set to disrupt food packaging industry with real-time spoilage and risk monitoring

The study defines biosensors as analytical devices that convert biological reactions into measurable signals, such as changes in electrical conductivity or color. These sensors, particularly electrochemical, pH, temperature, and gas sensors, can be engineered to detect food pathogens like Salmonella, E. coli, and Listeria, or environmental factors such as spoilage gases and acidity shifts. When embedded into packaging, biosensors can continuously monitor food freshness, contamination levels, and physical conditions such as temperature and humidity.

The food industry is continuously evolving in the face of climate change, global trade, and rising consumer expectations A comprehensive review titled “IoT-Enabled Biosensors in Food Packaging: A Breakthrough in Food Safety for Monitoring Risks in Real Time”, published in the journal Foods, explores how embedding biosensors into food packaging and connecting them through Internet of Things (IoT) networks could redefine the way we detect, prevent, and respond to contamination. The study, authored by researchers from institutions across the U.S., Canada, and Bangladesh, argues that these smart sensors can provide real-time monitoring of food quality and safety indicators, far surpassing traditional visual inspections or expiry date labeling.

The research outlines the current biosensor landscape, the integration of IoT technologies for data transmission, the challenges to implementation, and the immense opportunities such systems offer in transforming global food systems. With foodborne illness costing the U.S. $17.6 billion annually and up to 30% of food lost or wasted along the supply chain, the study makes a compelling case for shifting toward real-time, connected monitoring.

What are IoT-enabled biosensors and how do they work in packaging?

The study defines biosensors as analytical devices that convert biological reactions into measurable signals, such as changes in electrical conductivity or color. These sensors, particularly electrochemical, pH, temperature, and gas sensors, can be engineered to detect food pathogens like Salmonella, E. coli, and Listeria, or environmental factors such as spoilage gases and acidity shifts. When embedded into packaging, biosensors can continuously monitor food freshness, contamination levels, and physical conditions such as temperature and humidity.

These signals are transmitted through IoT technologies including Wi-Fi, Bluetooth, 5G, and near-field communication (NFC), allowing stakeholders such as producers, warehouse managers, retailers, and even end-consumers to receive alerts and monitor food status in real time. For instance, a refrigerated seafood container equipped with biosensors could instantly notify operators if the temperature exceeds safe limits or if microbial contamination is detected. Such interventions can prevent spoilage and illness, while reducing waste and enhancing supply chain transparency.

The review notes that these sensors can be customized for specific applications. For example, pH biosensors can be embedded in meat and fish packaging to detect spoilage through acidity levels. Similarly, gas sensors detect trace levels of ammonia or hydrogen sulfide, indicating degradation. These biosensors are now being developed using cutting-edge materials like graphene, MXenes, and biodegradable nanomaterials, which offer high sensitivity and eco-friendly integration.

Why hasn’t this technology gone mainstream yet?

Despite the promising capabilities of IoT-enabled biosensors, the study outlines several barriers preventing their widespread commercial use. Chief among them are technological limitations, integration complexity, and cost concerns.

Power supply is a persistent hurdle. Most biosensors require a stable power source to function, but embedding batteries into food packaging raises issues related to cost, safety, and sustainability. Researchers are exploring alternatives like energy harvesting from ambient light or motion, though these solutions are still in early development. Additionally, low-power sensor design and optimized data transmission protocols are critical to extending operational life without compromising accuracy.

Integration into existing packaging systems presents another challenge. Advanced sensors, especially miniaturized nano-biosensors, can be difficult and expensive to embed into mass-market packaging formats. The study cites the difficulty of integrating temperature-sensitive sensors into cartons for meat or dairy, noting that fabrication, compatibility testing, and system maintenance all increase production costs. Moreover, ensuring communication between IoT components across different brands and platforms necessitates standardized protocols, which are currently lacking.

Data security and privacy concerns also loom large. As biosensors collect and transmit vast amounts of data, including potentially proprietary or health-sensitive information, protecting that data from breaches or manipulation is essential. The authors emphasize the importance of end-to-end encryption, secure authentication, and compliance with data protection regulations such as the GDPR. Blockchain technology is identified as a promising tool to bolster trust, offering immutable traceability from farm to fork while safeguarding data integrity.

How will these technologies change the future of food safety?

Despite the challenges, the study projects a transformative future for food safety through the adoption of IoT-enabled biosensors. By embedding real-time monitoring capabilities into packaging, producers can dramatically reduce contamination risks, improve inventory management, and lengthen shelf life. Consumers, in turn, will benefit from dynamic expiry alerts sent via mobile apps, rather than relying on static “best by” dates which may not reflect actual spoilage.

The sensors can also play a vital role in allergen detection and personalized nutrition. For individuals with food sensitivities, biosensor-equipped packaging could scan for allergens like peanuts or dairy and transmit warnings through smartphones. IoT-connected systems could even deliver customized dietary recommendations based on a user’s health profile.

Additionally, the review points out strong synergies with blockchain networks. Integrating biosensor and IoT data with decentralized ledgers allows for tamper-proof tracking of food provenance and quality metrics. Retailers and consumers could scan a QR code on packaging to view the entire journey of a product, from origin and storage history to contamination alerts, empowering smarter, safer consumption choices.

The market potential is equally significant. The global packaged food market is projected to hit $500 billion by 2030, while the biosensor segment is expected to reach $50 billion. However, scaling the technology across this market will require policy support, industry-academic collaboration, and development of low-cost, sustainable packaging solutions.