From biosynthesis to food market translation of pullulan: AI-assisted production, structure-property-function interplay, regulatory perspectives, and commercialization.

Pullulan, a non-ionic exopolysaccharide produced by the yeast-like fungus Aureobasidium pullulans, has gained significant attention in the food industry due to its biodegradability, non-toxicity, and excellent film-forming properties. These characteristics make it suitable for sustainable food packaging, edible coatings, and other food-related applications. Despite its potential, commercial use of pullulan is limited by challenges in biosynthesis, high production costs, and varying regulatory requirements. While cost remains a barrier, advances in fermentation technology and raw material optimization are gradually improving feasibility. This review examines biosynthesis-structure-properties interplay and industrial-scale production, alongside the emerging role of artificial intelligence (AI) in optimizing production processes and enhancing pullulan performance, with a focus on its food applications. It discusses AI role in improving strain selection, fermentation conditions, and overall yield, as well as predicting functional properties such as film formation and antimicrobial activity. The review further evaluates regulatory challenges and global market dynamics, highlighting the impact of AI on the sustainable development of pullulan-based products. Overall, pullulan represents a promising biopolymer for replacing petroleum-based packaging and supporting sustainable food systems. By addressing production, regulatory, and functional challenges, and integrating AI-driven innovations, pullulan-based solutions can contribute to environmentally friendly and efficient food industry practices.