NEXT GENERATION CIRCULAR BIOBASED FLAGSHIP PACKAGING: A CATALYST FOR THE GREEN TRANSITION

Informations projet

TERRIFIC

N° de convention de subvention: 101157635

DOI

10.3030/101157635

Date de signature de la CE 12 Mai 2024

Date de début 1 Juin 2024

Date de fin 31 Mai 2028

Financé au titre de

• Food, Bioeconomy Natural Resources, Agriculture and Environment

Coût total

€ 26 512 551,25

Contribution de l’UE

€ 16 834 622,75

Coordonné par

NOVAMONT SPA
Italy

Periodic Reporting for period 1 - TERRIFIC (NEXT GENERATION CIRCULAR BIOBASED FLAGSHIP PACKAGING: A CATALYST FOR THE GREEN TRANSITION)

Période du rapport: 2024-06-01 au 2025-05-31

Résumé du contexte et des objectifs généraux du projet

The CBE-JU TERRIFIC project is a flagship initiative coordinated by Novamont demonstrating bio-based, circular packaging solutions at TRL 8. It aims to deliver 8 Flagship packaging options with enhanced barrier properties, boosting circularity and resource efficiency across their supply chains.
Six key objectives drive this project:
• Establishing a first-of-its-kind multi-purpose biorefinery to produce bio-based building blocks (1,4-bioBDO, C18-DCA) from sustainable feedstocks (sugars, vegetable oils) at TRL 8, with demonstrated replicability.
• Producing biopolyesters and biomaterials with over 95% renewable content and improved barrier properties using the novel C18-DCA.
• Developing 8 flagship bio-based packaging solutions (e.g. yogurt cups, coffee capsules, tea bags) using traditional industrial methods.
• Demonstrating the sustainability, circularity, and safety of these materials against existing benchmarks.
• Improving circularity and resource efficiency by validating multiple end-of-life scenarios compatible with various EU waste management frameworks.
• Evaluating the TERRIFIC concept's replicability via a multi-actor approach, fostering innovation and new business opportunities across the value chain.
TERRIFIC is a multidisciplinary collaboration involving 18 partners from 9 countries, spanning the entire value chain. The project's seven work packages, five of which are technical, ensure a structured implementation. Strong communication and dissemination efforts, involving various partners and a multi-actor interest group, will maximize progress and impact. The project also addresses potential barriers, outlining clear deliverables, tasks, milestones, and risk mitigation strategies to meet objectives on schedule.

Travail effectué depuis le début du projet jusqu’à la fin de la période considérée dans le rapport et principaux résultats atteints jusqu’à présent

Novamont's multi-purpose flagship biorefinery in Bottrighe is being designed and upgraded to produce innovative building blocks for flagship packaging solutions (FPS). In the first year, sustainable feedstock for fermentation was mapped, sourcing strategies defined, and supplier agreements finalized. Engineering designs for the plant were prepared and permitting secured.
Partners developed bio-based barrier materials. Key results include optimizing building block fermentation, synthesizing novel biopolyesters at TRL 7 showing improved WVTR, and preparing preliminary biomaterial formulations suitable for various conversion technologies. A pilot line for thermolaminated pulp trays was constructed, and an optical marker for bioplastics was successfully scaled and validated at TRL 7.
Technological partners has significantly advanced FPS development defining workflow for packaging preparation, collaborating on impact assessment, analyzing requirements and validation protocols. Converting lines have been established, producing initial prototypes like yogurt cups, coffee capsules, spun fibers, coextruded films, and expanded foams across all three technological trajectories (cellulosic laminated, rigid thermoplastic, flexible thermoplastic).
Initial steps for safety, sustainability, and circularity assessments include defining FPS value chains and calculating the carbon footprint of benchmark biomaterials (LCA). The methodology for Safe and Sustainable by Design (SSbD) has been defined and building block analysis performed. Analysis of benchmark biomaterial carbon footprint shows positive results towards project CO2 savings targets.

Progrès au-delà de l’état des connaissances et impact potentiel prévu (y compris l’impact socio-économique et les conséquences sociétales plus larges du projet jusqu’à présent)

TERRIFIC has made substantial progress in delivering results with strong potential impacts in the biobased and barrier packaging sector. The biomaterials under developing in the project are already demonstrating barrier properties that go beyond the current state of the art for biobased materials. Co-extruded films produced from biobased polyesters have already achieved barrier surpassing current benchmark biobased polyesters.
Preliminary LCA data shows that TERRIFIC formulations under development emit less CO2-equivalent per kilogram of material compared to both fossil and existing biobased references.
3 technological trajectories have been validated for the production of FPSs, ranging from biobased barrier films to thermoformed yogurt cups, injection moulded coffee capsules and spun fibers. All prototypes have been manufactured using relevant processes and have the potential to expand the portfolio of exploitable biobased and barrier FPSs with functional properties and compatibility with EoL options, including composting, mechanical and chemical recycling, and repulping.
The project has implemented an integrated business planning strategy and IPR management approach, identifying key exploitable results, with tailored pathways for commercialization and replication. A multi-actor interest group has been established to guide market alignment and stakeholder engagement. Surveys and direct dialogue with brand owners have informed the design and acceptance testing of consumer-oriented packaging formats like coffee capsules and snack packs. These interactions confirm that TERRIFIC solutions respond to clear market demands for sustainability and functionality.