Cellulose-based films and coatings could replace conventional fossil-based plastics, according to the findings of a project run by LUT University and VTT Technical Research Centre of Finland.
The F3 – Films for Future bio-based materials research programme, which was completed in March, demonstrated the feasibility of recyclable, biodegradable films and coatings at pilot-scale across multiple applications.
The technology used by the programme enables cellulose to be processed as a polymer rather than a fibre, resulting in transparent bioplastics films with mechanical and barrier properties that can potentially be used as standalone, transparent packaging material with inherent biodegradability, the researchers found.
Meanwhile, coatings have been engineered for both recyclability within fibre-based systems and biodegradability where required.
Working towards commercialisation
The programme will now focus on scaling the technology for commercial applications, initially in dry food packaging, bakery products, and fibre-based packaging that require transparent barrier layers.
The films are said to provide oxygen barrier performance (oxygen transmission rate below 1 cubic cm per m2 per day) comparable to conventional plastics at 23°C and 50 per cent RH, while the coatings enable oxygen (OTR below 0.2 cubic cm per m2 per day) and grease barrier (Kit level 12) functionality in recyclable fibre-based packaging systems.
Further development will target barrier performance under humid conditions, as well as the integration of multiple functionalities within a single material system, VTT said. Digitalisation, including sensor-enabled or connected packaging, is also expected to play a role in future applications.
“The key challenge has not been whether alternative materials exist, but how to process them in a way that meets industrial requirements,” said Vinay Kumar, senior scientist at VTT.
‘Future-ready material platform’
“What has now been demonstrated is a future-ready material platform that offers an alternative to plastics, combining sustainability with the capability to integrate into existing manufacturing and recycling systems. We see strong potential to develop this further together with industry partners.”
Riku Talja, development manager at Metsä Board, added: “From an industry perspective, scalability and system compatibility are critical factors. Solutions that align with current converting technologies and recycling infrastructure are far more likely to transition from pilot-stage innovation to industrial use.”
Last year, researchers in Japan developed a new type of plant-based plastic that they claim fully degrades in seawater without leaving behind microplastics.
The material is made from plant cellulose, and is said to break down in other natural environments without contaminating soil or harming animals and plants.
