Periodic Reporting for period 3 - PULPACKTION (Optimised moulded pulp for renewable packaging solutions)
Berichtszeitraum: 2019-10-01 bis 2021-09-30
The base of PULPACKTION innovation, lies in the use of renewable, bio-based, bio-degradable and carbon-neutral cellulose fibers, coupled with bio-based and bio-degradable bio-polymers for barrier properties.
Using raw materials from Europe, cellulose and starches from both agri- and forest culture, we are reducing dependence on imported crude oil, contributing positively to development of local, sustainable economies inside Europe.
The project benefits Europes ambitions to develop sustainable and innovative technologies and economies in a green-tech sector.
Five main specific objectives were identified on the DoA, and are listed below:
Objective 1: Improvement of existing wood pulp wet moulded materials for the development of tailored-to-purpose pulps. (WP2)
In this objective we have analyzed 12 different kinds of pulp, both mechanical pulp, sulphite pulp and sulphate pulp. Once evaluated, these formulations were upscaled as trays.
Objective 2: Improvement of current technology of cellulose wet moulded productions. (WP3)
Wet moulded process technology enhancements were focused to reach forming and pressing speeds more competitive than currents, reduce cycle and drying time and consequently improving final package industrial process and product characteristics.
Objective 3: To produce specific bio-based plastics materials to reach final product packaging and shelf-life requirements (WP4)
To fulfil final product’s packaging requirements by improving the properties of existing bio- based materials, leading to the substitution of current fossil-based packaging for 100% bio- based alternatives.
Objective 4: To develop sustainable final packaging materials able to reach targeted renewability criteria’s cited as sustainability indicators (WP1, WP5, WP8)
The reduction of 50% of CO2 emissions will be tackled in PULPACKTION project from several ways.The objective of reducing the overall carbon emission of more than 50% compared to current trays was demonstrated in the project.
Objective 5: To validate final packages in an industrial environment. (WP1, WP6, WP7))
Final demonstrators were obtained and validated at Dafgards and Angulas. The interaction between product-package and the distribution conditions simulation were performed in order to guarantee the industrial upscale at the end of the project. These validation was considered as positive against conventional packaging.
Work in WP4 was still fine tuned within the last period to find the optimal properties and process conditions for the bio-based coating and films.
Work in QP1 was also active in organizing consumer panels to evaluate the consumer response to the proposed demonstrators.
The results from WP8 regarding found good and expected results regarding the LCA. Carbon foot print is substantially lower than for conventional plastic packaging alternatives. However, compostability according to EAN-standard was not reached during the measuring period. Degradation does take place but at slower speed than the standard allows, but an acceptable compromise to meet other important objectives of the project.
Two brand owners were active in analyzing the proposed demonstrators at industrial scale. The results from the brand owners were encouraging, demonstrating that the packages fulfill the requirements of the market in terms of process, quality, hygiene and barrier characteristics.
The results of the project benefit the individual consortium members that can commercialise various innovations and validations of materials.
Dissemination has been done by individual companies on web pages, LinkedIn, news articles and releases as well on social media.
The demonstrator proves that bio-based moulded fibre packaging for food products can be a part of the solution for the environmental issues that we are facing globally, with plastic pollution, CO2 emissions and dependance on fossile raw materials. As we currently can see, the industry is rapidly evolving in Europe with many new start up enterprises investing into this industry. With the gained knowledge and demonstrated options, we believe that the consortium members are in a position to support and assist in the growth of this market and industry going forward.
As moulded pulp production increases in Europe, it increases the domestic production in Europe, and thus decreases the import of similar products with long supply chains. This is sustainable and increases the industrial know-how in Europe. European based production is also more sustainable as strict health & safety procedures are in place in Europe. There are also limitations and recommendations and wide public interest for use of various chemicals (such as PFAS) in the production process, which cover health and environment aspects, that benefit the consumer and society at large too.