FINLAND – VTT Technical Research Centre of Finland conducted a pilot-scale study aimed at identifying alternative raw materials for rigid plastic packages.
The study successfully achieved remarkable maximum limits for its highly extensible formable cellulose-based webs, which are utilized in rigid packaging applications.
The findings facilitate the production of a diverse array of environmentally friendly 3D packaging options that were previously unachievable.
Conventional commercial boards typically exhibit an extensibility range of 3-6%, while the most advanced commercially available formable boards demonstrate an extensibility range of 10-18%.
By employing foam forming technology, VTT has achieved a maximum extensibility of 30%. This feature allows brand owners to utilize rigid, cardboard-like packaging in order to cater to consumers who are seeking to purchase products that are more environmentally friendly.
This advancement in material technology allows food brands, such as those producing cold cuts, to expand the size of their cardboard-like packaging from 75 grams to 200-250 grams.
By modifying the tray forming procedure and altering the tray dimensions, it is possible to manufacture even larger packages resembling cardboard. Polypropylene film, being one of the most widely utilized polymers globally, exhibits an extensibility of up to 300%.
“Our invention currently presents a feasible and sustainable alternative in the market,” states Jarmo Kouko, the Research Team Leader at VTT.
“There has been extensive academic research conducted globally on the eradication of plastics; however, the issue lies in the limited implementation of these findings beyond the realm of research.
“We are immensely enthusiastic and proud of the outcomes from our pilot-scale study, which unequivocally demonstrates the commercial potential of our rigid cellulose-based packaging.”
In light of the Single-use Plastics Directive and the European Commission’s proposal for Packaging and Packaging Waste Regulation, certain plastic items such as expanded polystyrene (EPS) food containers and cups have been prohibited in the European Union since 2021.
Additionally, producers of single-use plastic products are now required to bear the costs associated with waste management for these items.
Solutions such as VTT’s foam-formed cellulose-based packaging offer suppliers a sustainable and cost-effective alternative to single-use plastic.
The collaboration between VTT and gruppo x di x gruppo s.r.l. highlights the significance of this development.
The Lappeenranta-Lahti University of Technology (LUT) and VTT Technical Research Centre of Finland have successfully integrated the product into existing product packaging lines without any modifications to the process.
This seamless integration makes it cost-effective and convenient for brands to adopt the product as a sustainable alternative to plastic packaging.
According to Kristian Salminen, the Lead of Bio-based Products at VTT, this development has the potential to be a significant game-changer.
The research program, in collaboration with 54 companies and the Regional Council of Central Finland, has focused on upscaling promising alternatives for plastic products.
The findings of this research will be presented by the VTT team at The Greener Manufacturing Show 2023 in Cologne, Germany, scheduled for November 8-9.
