Fibre-based packaging

Cardboard is a many-sided packaging material because of its strength, printability and sustainability (can be recycled). However, the requirements imposed on packaging nowadays go beyond its physical ability to protect the product. Qualities such as barrier against gases, fastening by seals, excellent print results and information provision are now almost part and parcel of conventional plastics. The next step is to develop new innovative solutions to incorporate this range of qualities into renewable raw materials (wood fibres and bio-polymers).

Innovative solutions

The European project Sustainpack aims to create a new set of track records in packaging concepts based on renewable raw materials. It has a strong emphasis on the market and the consumer; its approach is chain-based. Market investigations and interviews with involved parties in the entire chain should pave the way for the technology to be developed. Innovations are expected in various areas.

Nano-reinforcement

The balance between the amount of material and its strength is of great importance in packaging, in relation to costs and robustness in the chain. In Sustainpack, research will be conducted into the workings of cellulose fibres and nano-clay particles in nano-scale. Chemical modification lessens the internal cohesion in cellulose and minerals such that the structures can be broken into nano-particles. By integrating this pioneering technology in existing pulverisation operations, the strength of fibre-based materials can be increased, which will eventually lead to a material reduction of 30%.

Protective coatings

New protective packaging shall be developed by coating cardboard. Barrier properties and resistance against mechanical distortions can be improved by use of nano-composites, micro-encapsulation and 'smart polymers' (polymers with modified properties which are activated by moisture, temperature and pH). Innovative print techniques can enable cost-effective tailor-made materials to be produced with specific reinforcement. Spot printing, for example, can reduce water absorption at critical points, such as corners exposed after cutting.

Extra dimension

Three-dimensionally-shaped products made from renewable cellulose-based composites can be a sustainable alternative for petroleum-based materials in packaging and protective applications. Developments are taking place in two ways. Firstly, organic-decomposable polymers can be strengthened with cellulose fibres to result in constructions with or without foam. Secondly, thorough modifications of cellulose fibres are being researched into with the aim of achieving co-continuous thermo-formable composites.

Communicative packaging

Another important part of the project Sustainpack is the development of sustainable packaging for communication purposes. An interdisciplinary approach in printing and coating technologies, ICT and packaging design is being adopted to achieve fibre-based packaging integrated with pro-active communication technology. Sensors and bio-active compounds can be developed based on future organic/mineral materials, conductive polymers and micro-antennas for cordless communication. The ability to monitor the chain conditions around the products forms the essence of quality-based tracking & tracing, and this will increase food safety.

Results

The knowledge to be generated in the project will take on concrete form in innovative packagings. Examples are new microwave packagings, moisture-resistant and gas-tight boxes, prints which guarantee brand-protection, intelligent packaging and paper-based form-fill-seal packaging options. Wageningen UR Paper and Board/Agrotechnology and Food Innovations is an important player in the Sustainpack project. Research will be performed in the area of material improvement, composite materials and communicative packaging.

Project participants

An European consortium of 14 research institutes, 11 universities and 8 industrial companies has been formed to undertake this research project. The project coordinator is from the Packforsk institute in Sweden. The total budget is almost 30 million Euros.

Important aspects of this mammoth project are maximum integration within the European knowledge network and optimal spread of (research) results to the European industry. Involvement from middle and small companies is particularly being stimulated. Throughout the duration of the project, these companies will be approached to actively participate in it, by testing and evaluating new materials or technologies. Companies can also participate as sponsors. Co-financing a research institute will allow companies access to the project group of the institute involved; extensive sponsoring enables companies to have a say in the working plans of the related project part.