Periodic Reporting for period 1 - REDYSIGN (Resource-efficient processes for the production and circularization of innovative RECYclable-by-DeSIGN fresh meat smart packaging from wood)
Berichtszeitraum: 2023-10-01 bis 2025-03-31
The EU faces a plastic packaging waste crisis, generating 15 Mton annually with only 40% recycled. Fresh meat packaging is a major contributor, using non-recyclable, multi-material products that harm the environment and human health. In response, the EU has introduced initiatives like the Green Deal and Packaging and Packaging Waste Regulation to shift towards sustainable alternatives. However, current products and recycling schemes are insufficient, necessitating innovative solutions.
The REDYSIGN project addresses this issue by developing a fully biobased, recyclable alternative for fresh meat packaging. It employs resource-efficient technologies to produce a lignocellulosic fibre-based packaging product from sustainably managed wood, featuring a barrier-coated tray, absorbing pad, and sensor-equipped film. A new recycling scheme for food-contaminated waste is also being developed. As a Research and Innovation Action, the project focuses on market-oriented innovation, aiming to commercialize solutions as they are developed. By developing this biobased packaging solution, REDYSIGN contributes to the EU's goals of reducing plastic waste and promoting sustainable packaging practices.
The REDYSIGN project addresses this issue by developing a fully biobased, recyclable alternative for fresh meat packaging. It employs resource-efficient technologies to produce a lignocellulosic fibre-based packaging product from sustainably managed wood, featuring a barrier-coated tray, absorbing pad, and sensor-equipped film. A new recycling scheme for food-contaminated waste is also being developed. As a Research and Innovation Action, the project focuses on market-oriented innovation, aiming to commercialize solutions as they are developed. By developing this biobased packaging solution, REDYSIGN contributes to the EU's goals of reducing plastic waste and promoting sustainable packaging practices.
The REDYSIGN project, funded by the Circular Biobased Europe Joint Undertaking, is on track after 18 months, with progress going according to schedule. The initial phase has focused on Work Packages (WP) 2, 3, and 4, driving technical activities. These WPs cover transforming wood into high-value materials, developing smart packaging solutions (sensors, markers, and detection technology), and redesigning packaging parts (tray, pad, and film) to be fully biobased and recyclable. WPs 1, 6, and 7 are also making progress, while WP 5 is pending and will start soon.
In more detail, many technical activities have been performed over the first period of the project. For example, the high-consistency functionalization of lignocellulosic fibers has been deeply explored, by investigating four processes and several chemical and enzymatic routes. Successful treatments included phosphorylation, periodate oxidation, and laccase-mediated hydrophobization. Additionally, research on conical refiner and processing of functional TMP fibers into micro-nanofibers is showing promising results in fiber disassembly. The development of a wood sugar-based adhesive showed satisfactory adhesion properties, paving the way for its application in future tray-lidding film adhesion.
In the area of smart packaging, two distinct identification markers have been developed for use in REDYSIGN tray and absorbing pad products, an innovation that will enable improved sorting prior to packaging recycling operations. The project has also made progress in the detection of those traceability markers and contaminants, both in controlled lab and real-world, dynamic situations, combining machine vision with spectroscopy. Moreover, the development of anti-spoilage sensors for smart food packaging resulted in two innovative sensors, including a low-cost, printable device and a cold chain sensor with a memory option. The anti-spoilage sensor performed particularly well in testing, ensuring product quality and safety.
The project applied the Safe and Sustainable by Design (SSbD) concept to develop sustainable packaging solutions, identifying thirteen eco-design strategies that integrate sustainability and safety. Production trials of plastic-free trays commenced, resulting in some promising initial results. The identification marker was successfully incorporated to the wet-molded production process, making the trays detectable through Raman spectroscopy. In parallel, the dry-molding tray production process showed promising results, with the integration of a top coating made from an enzymatically-treated wood fraction successfully conferring hydrophobicity to the final product.
Research on the development of a fully biobased and sprayable barrier coating based on wood derivatives. Formulations based on lignin are being developed and some preparations have already proved to form a uniform hydrophobic layer on the cellulosic substrate surface, increasing its water resistance. Additionally, two independent technologies, dry-airlaids and ice-templating, are being explored for absorbing pads production, with promising results in the ice-templating approach.
Overall, the REDYSIGN project is making significant progress in developing innovative solutions for biobased packaging, addressing the need for sustainable and safe packaging alternatives. While challenges remain, the project is on track to achieve its goals of replacing non-circular plastic packaging with biobased alternatives.
In more detail, many technical activities have been performed over the first period of the project. For example, the high-consistency functionalization of lignocellulosic fibers has been deeply explored, by investigating four processes and several chemical and enzymatic routes. Successful treatments included phosphorylation, periodate oxidation, and laccase-mediated hydrophobization. Additionally, research on conical refiner and processing of functional TMP fibers into micro-nanofibers is showing promising results in fiber disassembly. The development of a wood sugar-based adhesive showed satisfactory adhesion properties, paving the way for its application in future tray-lidding film adhesion.
In the area of smart packaging, two distinct identification markers have been developed for use in REDYSIGN tray and absorbing pad products, an innovation that will enable improved sorting prior to packaging recycling operations. The project has also made progress in the detection of those traceability markers and contaminants, both in controlled lab and real-world, dynamic situations, combining machine vision with spectroscopy. Moreover, the development of anti-spoilage sensors for smart food packaging resulted in two innovative sensors, including a low-cost, printable device and a cold chain sensor with a memory option. The anti-spoilage sensor performed particularly well in testing, ensuring product quality and safety.
The project applied the Safe and Sustainable by Design (SSbD) concept to develop sustainable packaging solutions, identifying thirteen eco-design strategies that integrate sustainability and safety. Production trials of plastic-free trays commenced, resulting in some promising initial results. The identification marker was successfully incorporated to the wet-molded production process, making the trays detectable through Raman spectroscopy. In parallel, the dry-molding tray production process showed promising results, with the integration of a top coating made from an enzymatically-treated wood fraction successfully conferring hydrophobicity to the final product.
Research on the development of a fully biobased and sprayable barrier coating based on wood derivatives. Formulations based on lignin are being developed and some preparations have already proved to form a uniform hydrophobic layer on the cellulosic substrate surface, increasing its water resistance. Additionally, two independent technologies, dry-airlaids and ice-templating, are being explored for absorbing pads production, with promising results in the ice-templating approach.
Overall, the REDYSIGN project is making significant progress in developing innovative solutions for biobased packaging, addressing the need for sustainable and safe packaging alternatives. While challenges remain, the project is on track to achieve its goals of replacing non-circular plastic packaging with biobased alternatives.
Some notable achievements, so far, include:
- The development of a highly-efficient process for the functionalization of lignocellulosic fibers under a high-consistency regime: the impact lies, first, in its water usage reduction that can account for a >95% compared to current methodologies, and the reduction of generated effluents associated to it and, second, in the highly efficient use of the chemicals which, according to currently available data (work is still ongoing), can be reduced by >75%.
- The development of an integrated system to identify the tray and evaluate the presence of contaminants on it: this feature will be key in improving the sorting step of the waste management, and thus in improving the subsequent recycling operations.
- The development of a plastic-free, water-resistant tray produced through the dry-forming method: the impact combines the new energy- and water-efficient process (with energy and water savings estimated in, respectively, 80% and 70% compared to current processes) and the development of a plastic-free, biobased (and we expect, recyclable) hydrophobic coating.
- The development of a polymer-free, all cellulose absorbing pad with a stunning absorption capacity of 23 times its weight under load. The impact resides in its recyclability (still to be demonstrated but likely) due to the absence of polymers.
- The development of a highly-efficient process for the functionalization of lignocellulosic fibers under a high-consistency regime: the impact lies, first, in its water usage reduction that can account for a >95% compared to current methodologies, and the reduction of generated effluents associated to it and, second, in the highly efficient use of the chemicals which, according to currently available data (work is still ongoing), can be reduced by >75%.
- The development of an integrated system to identify the tray and evaluate the presence of contaminants on it: this feature will be key in improving the sorting step of the waste management, and thus in improving the subsequent recycling operations.
- The development of a plastic-free, water-resistant tray produced through the dry-forming method: the impact combines the new energy- and water-efficient process (with energy and water savings estimated in, respectively, 80% and 70% compared to current processes) and the development of a plastic-free, biobased (and we expect, recyclable) hydrophobic coating.
- The development of a polymer-free, all cellulose absorbing pad with a stunning absorption capacity of 23 times its weight under load. The impact resides in its recyclability (still to be demonstrated but likely) due to the absence of polymers.