Sustainable surface protection by glass-like hybrid and biomaterials coatings

Project Information

BIO-SUSHY

Grant agreement ID: 101091464

DOI

10.3030/101091464

EC signature date 18 November 2022

Start date 1 January 2023

End date 31 December 2026

Funded under

• Digital, Industry and Space

Total cost

€ 4 815 296,25

EU contribution

€ 4 815 296,25

Coordinated by

MATERIA NOVA
Belgium

Periodic Reporting for period 2 - BIO-SUSHY (Sustainable surface protection by glass-like hybrid and biomaterials coatings)

Reporting period: 2024-01-01 to 2025-06-30

Summary of the context and overall objectives of the project

Per- and polyfluoroalkyl substances (PFAS) are widely used to provide water and oil repellency in applications, such as textiles, food packaging, and paints. However, these chemicals are highly persistent accumulating in the environment, wildlife, and human blood, leading to global health and ecological concerns. BIO-SUSHY addresses this challenge by developing innovative, PFAS-free coating solutions that align with the EU’s Chemical Strategy for Sustainability, aiming for a toxic-free environment. The project focuses on bio-based approaches to create durable water- and oil-repellent coatings, validated across three key markets: textile, food packaging, and cosmetic glass packaging.
BIO-SUSHY applies the Safe-and-Sustainable-by-Design (SSbD) concept, integrating circularity and eco-design principles from the outset. Using multidisciplinary methods—including computational modeling, data-driven approaches, rapid screening, and life cycle assessment—the project ensures safety are embedded in organic and hybrid coating formulations. This reduces the environmental impacts, avoids volatile organic compound emissions, and supports end-of-life options like composting or recycling.
By demonstrating the effectiveness of its SSbD-driven innovations, BIO-SUSHY paves the way for Europe’s transition to sustainable coating materials. These advancements enhance functionalities in consumer products, boost resilience in strategic value chains, and could reduce PFAS-related health risks for millions while supporting circular economy goals. The project’s scale included potential applications in broader industries, contributing to EU targets for reducing persistent pollutants.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

BIO-SUSHY has developed three PFAS-free coatings using an SSbD approach, supported by computational modeling, and will validate them in case studies of food trays, textile, and cosmetic glass packaging.
For food packaging, PFAS-free thermoplastic powder coatings based on polybutylene succinate (PBS)/lignin and polyhydroxyalkanoates (PHA) have been developed for cellulosic materials, achieving hydrophobic properties and excellent grease resistance. These coatings have 80-98% bio-based content, with toxicity assessments ongoing under the SSbD framework. Applied via spray on one side of paper, they enable dry storage at under 25°C for up to two years. Planned tests include migration, compostability, and repulping per regulations, with scale-up focusing on extrusion and dry powder technologies.
For textiles, partially bio-based hybrid sol-gel coatings like Pearlisol (28% bio-based per EN 16785-1) and water-based Depersol/Depersol-Green (23-46% bio-based) have been developed. Pearlisol provides hydrophobic and oleophobic properties on polyester/cotton blends and cotton, per ISO 4920 spray tests. Depersol formulations, applied via dip-pad-dry-cure, exhibit strong hydrophobicity and laundering resistance, performing best on polyester but tested on blends. SSbD ensured no persistent pollutants or hazard pictograms, with life cycle assessment progressing. Next steps include scalability, adhesion optimization, and semi-industrial processing.
For cosmetic glass packaging, bio-based (GlideBioCoat) and polydimethylsiloxane (GlideSilCoat)-hybrid coatings have been formulated, delivering hydrophobic (water contact angle >90°) and oleophobic (hexadecane contact angle >35°) properties. SSbD steps replaced high-toxicity components with safer alternatives. Demonstrated on microscope slides and inner glass containers, these show promising sliding properties (see attached image). Bio-based carbon content is 5-15%, with aims to reach 25%.
Computational tools for simulations, data harmonization, and FAIRification, QSAR models, and molecular dynamics have supported coating properties predictions. SSbD criteria established hazardous property data, and experimental screening tests on coating components have provided preliminary results for all five steps of the SSbD framework, including life cycle assessment (LCA) and social-LCA, which offer insights into environmental footprints and societal impacts.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

BIO-SUSHY has advanced SSbD-driven bio-based coating for water- and oil repellency, validated in targeted value chains for textiles, food packaging, and cosmetic glass. Innovations include thermoplastic powders with 80-98% bio-based content for grease-resistant food trays, hybrid sol-gel coatings with 5-46% bio-based content for hydrophobic/oleophobic textiles, and glass, all of which are PFAS-free and match the performance in repellency and durability of traditional PFAS coatings.
The project’s computational tools allow reuse of experimental data and fill gaps via QSAR, providing comprehensive material insights. This framework enhanced safety and sustainability criteria for novel coatings, free from hazardous additives, with applicability extending to wider markets.
Potential impacts include curbing PFAS pollution, supporting EU green goals, and scalable applications in consumer goods. For uptake, needs include further demonstration in industrial settings, market access via pilots, IPR protection and standardization. Regulatory frameworks favoring SSbD could accelerate commercialization and international adoption

Test on coated glass packaging

Sikemia scaled up bio-based linker synthesis

BIO-SUSHY coatings for textile

Toxicology assessment of coating components

BIO-SUSHY Data Workflow

Mini release reactor use in combination with bio-membrane sensor to assess toxicity of coatings

Coarse-grained models and atomistic simulations of BIO-SUSHY coatings

Hydrophobic PFAS-free polymer coating on paper