Pomelo essential oil has good antioxidant and antimicrobial properties. The objective of this study was to modify the active packaging loaded with essential oil through low-energy emulsification, in order to achieve both film-forming and emulsifying properties of tamarind gum, and to investigate the surface activity of melatonin in the emulsion. When α:β mixing ratio of 60:40, the resulting film solution exhibited favorable apparent viscosity and reduced emulsion flocculation and precipitation phenomena. Particle size distribution analysis and optical microscopy results demonstrated that the obtained emulsion was uniformly dispersed at an α:β mixing ratio of 60:40, with droplet diameters mainly concentrated within the range of 1–100 μm. After undergoing film-forming treatment, E-3-F (α:β mixing ratio of 60:40) exhibited a smoother and more compact microstructure, leading to significant improvements in mechanical properties and barrier performance. Laser confocal microscopy imaging revealed that the addition of melatonin further reduced interfacial tension between oil and water, while simultaneously weakening hydrophobic interaction forces among oil droplets, thereby effectively inhibiting droplet aggregation behavior. Moreover, incorporation of melatonin also enhanced material compactness and imparted excellent antioxidant effects to the packaging material. Consequently, this study ultimately unveils potential for low-energy emulsification combined with melatonin application in bio-based packaging field while providing novel insights into developing multifunctional bio-based packaging.
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