Periodic Reporting for period 1 - FlexFoam (Sustainble alternative to flexible packaging)
Reporting period: 2023-01-01 to 2023-12-31
Paptic Foam product and technology offers a unique thin, flexible and soft sustainable alternative to plastics in flexible packaging. It solves all the bottlenecks that have hampered the market introduction of alternative materials so far, namely scalability of manufacturing, cost-efficiency and compatibility with the standard processes of the packaging industry.
The patented Paptic Foam material offers a unique combination of sustainability credentials of paper (biobased, renewability, recyclability, compostability) with the versatility of plastics, and textile-like soft and flexible hand feel characteristics. The material is recyclable together with paper/board.
The scalability of the patented Paptic Foam production technology is superior compared to most of the other technologies replacing plastics. As Paptic technology can be taken into use on the already existing paper machines the availability of Paptic materials can be guaranteed while the demand increases. The paper industry is struggling with over-capacity and licensing of the Paptic technology and brand offers a quick route to enter the packaging market.
The FlexFoam project focuses on the realization of the first industrial foam production line which will act as a pilot case and model for further paper line conversions. The first commercially viable foam line will be a key enabler for licensing business model options.
A major part of the project addresses establishing partnership and business model between Paptic and the owner company of the asset to be converted as well as building the market and locking interest of first customers. These are activities which bear a lot of unknowns and risks and it is important to pay adequate attention and resources to them.
The patented Paptic Foam material offers a unique combination of sustainability credentials of paper (biobased, renewability, recyclability, compostability) with the versatility of plastics, and textile-like soft and flexible hand feel characteristics. The material is recyclable together with paper/board.
The scalability of the patented Paptic Foam production technology is superior compared to most of the other technologies replacing plastics. As Paptic technology can be taken into use on the already existing paper machines the availability of Paptic materials can be guaranteed while the demand increases. The paper industry is struggling with over-capacity and licensing of the Paptic technology and brand offers a quick route to enter the packaging market.
The FlexFoam project focuses on the realization of the first industrial foam production line which will act as a pilot case and model for further paper line conversions. The first commercially viable foam line will be a key enabler for licensing business model options.
A major part of the project addresses establishing partnership and business model between Paptic and the owner company of the asset to be converted as well as building the market and locking interest of first customers. These are activities which bear a lot of unknowns and risks and it is important to pay adequate attention and resources to them.
During the first period we finalized the design of Paptic foam technology concept by demonstrating each unit step separately at different pilot facilities. We managed to reach or exceed all goals on production parameters. We have thus the readiness to design an industrial scale production line. The technology risks have been reduced during the project and the technology is viable for scale up.
A first detailed production line was designed with a major Scandinavian pulp and paper company at their site. The specific site would have needed more basic repairs which were not related to foam investment, as well as other changes, making the business case unattractive. Another site was given as an option and Paptic technology fitting was started on that site. This lead partner decided to pull out of the foam scale-up and collaboration before getting on detail level of the second site. The company is experiencing cash flow issues, and the newly appointed CEO will focus on getting the core business on track.
During the first year the importance of having several scale-up partners in the loop became evident. We have managed to start a dialogue with several companies as potential scale-up partners. As the risk with lead partner pulling out realized, we will intensify the search of a new scale-up partner.
As we understand that the market generation is so vital, we intend to start collaboration with Fiber-X (a Finnish paper technology piloting facility) and have the continuous process validated as well as product produced at a scale which allows building customer traction.
A first detailed production line was designed with a major Scandinavian pulp and paper company at their site. The specific site would have needed more basic repairs which were not related to foam investment, as well as other changes, making the business case unattractive. Another site was given as an option and Paptic technology fitting was started on that site. This lead partner decided to pull out of the foam scale-up and collaboration before getting on detail level of the second site. The company is experiencing cash flow issues, and the newly appointed CEO will focus on getting the core business on track.
During the first year the importance of having several scale-up partners in the loop became evident. We have managed to start a dialogue with several companies as potential scale-up partners. As the risk with lead partner pulling out realized, we will intensify the search of a new scale-up partner.
As we understand that the market generation is so vital, we intend to start collaboration with Fiber-X (a Finnish paper technology piloting facility) and have the continuous process validated as well as product produced at a scale which allows building customer traction.
We are proud to report that we have been able to demonstrate production speeds up to 700 to 1000 m/minute for head box and wire speeds in trials testing these unit operations. According to our knowledge this is over 3 times the speed of commercial foam forming process references from the glass fibre non-woven industry.
We have also made an invention related to business model and technology when converting traditional paper and board machines to foam technology. The patent has not yet been filed, but the search report related to inventiveness was positive and the patent drafting is ongoing. This patent application will strengthen our licensing opportunities.
We have also made an invention related to business model and technology when converting traditional paper and board machines to foam technology. The patent has not yet been filed, but the search report related to inventiveness was positive and the patent drafting is ongoing. This patent application will strengthen our licensing opportunities.