CLAYMBAR proposes an innovative technology for the manufacturing process of rigid plastic packaging for the food sector. Thanks to the inclusion of permeability barriers made upon advanced materials (nanocomposites based on nanoclays) we are able to optimise the injection moulding process to apply the masterbatch into the rigid plastic and so greatly improve the shelf-life of everyday products (infant food, dairies, sauces, etcetera). Moreover, we are able to do this cost-effectively, as our technology optimises the injection moulding manufacturing process to apply the masterbatch into the rigid plastic, which is very attractive for the industry as it is a much less energy consuming process.
During this 6-month feasibility study we’ve validated both the technology and the business opportunity:
1) We have conducted a thorough market analysis to consolidate the demand for a new plastic solution for the food market segment selected (sauces, dairy products and infant feeding); to define the right strategies to penetrate into the market; to assess market competitors.
2) We have defined the target composition of the final masterbatches, as well as the concentration of nanoclays, dispersants, and other elements, performing near-real scenario tests on the final product, and analysis at expert external laboratories.
3) We have identified the critical tasks to produce quality masterbatches and the characteristics of the injection moulding equipment, performing near-real scenario tests on the final product, and analysis at expert external laboratories.
4) We have defined a technology transfer strategy to identify possible agreements with stakeholders in other segments of the food sector. Thanks to the participation of HEINZ during Phase 1, our feasibility study will also provide first-hand information on consumer needs and how best to meet them.
5) We have conducted an operating costs study to define the requirements for manufacturing the final product – including staff planning, labour costs, injection equipment, services, raw materials (nanoclays, PP, others), and other capital costs.
6) We have built 5-years financial projections for both MPG and CS business including: revenue, cash-flow, profit and loss and balance sheet.
7) We have conducted a risk analysis to define the challenges of manufacturing CLAYMBAR.
8) We have defined company agreements. Definition of an adapted structure of the companies to face the business challenges (including technical manager, business developer, commercial network).
9) We have conducted a thorough freedom to operate study.
In order to create a convincing and attractive commercial product, we still have to take the following specific actions to achieve the following business objectives:
1) Conduct a thorough environmental impact analysis to fully estimate the potential environmental impacts of nanotechnology (absence of risk and benefit from being an energy efficient process).
2) Conduct a thorough food contact analysis to consolidate the process to achieve authorisation as a packaging valid product for the food sector in the EU.
3) We have to define the final formulation for the masterbatch and design the final industrial equipment to be used in industrial facilities.
