Periodic Reporting for period 2 - Nature Fresh (Development and Commercialisation of a complete compostable film packaging system)
Reporting period: 2020-10-01 to 2021-12-31
Only 14 % of plastic packaging is recycled, so about 8M tons of plastic is dumped into oceans per year. Recycling these single-use disposable plastics is the best strategy to curb plastic pollution. The ideal would be a packaging film that is 100 % recycled or biologically decomposable. In response to this need, Nature Fresh project aims to develop an industrial compostable film packaging solution for the fresh food packaging markets. This solution includes the film, labels and the full machine periphery to process and handle the compostable film easily. Furthermore, it is target of the project to identify and test an industrial compostable label. Since film and label are not getting separated in the waste disposal process, only if both components are compostable, a fully green footprint can be realized.
Compostable plastics can break down, safely and relatively quickly, by biological means to completely biodegrade when composted. So, there is a need of a full compostable wrapping packaging solution (film, label and tray) along with an easy-to-use and maintain, cost effective packaging machine.
In response to this need, the consortium led by Fabbri Group has developed a platform technology ‘Nature Fresh’ completely compostable film packaging solution, targeting the fresh food packaging markets. Nature Fresh delivers retailers, food processors, and common public direct environmental benefits, and support in sustainability initiatives. Through the project, the Consortium has carried out activities such as optimization and commercial scale manufacturing of the compostable film, design and development of the wrapping machines, evaluation and testing of the compostable labels, design and development of a compostable label applicator system, gain regulatory approvals and conduct end-user trials to gain market acceptance and a swift market entry by Q2-2022.
Compostable plastics can break down, safely and relatively quickly, by biological means to completely biodegrade when composted. So, there is a need of a full compostable wrapping packaging solution (film, label and tray) along with an easy-to-use and maintain, cost effective packaging machine.
In response to this need, the consortium led by Fabbri Group has developed a platform technology ‘Nature Fresh’ completely compostable film packaging solution, targeting the fresh food packaging markets. Nature Fresh delivers retailers, food processors, and common public direct environmental benefits, and support in sustainability initiatives. Through the project, the Consortium has carried out activities such as optimization and commercial scale manufacturing of the compostable film, design and development of the wrapping machines, evaluation and testing of the compostable labels, design and development of a compostable label applicator system, gain regulatory approvals and conduct end-user trials to gain market acceptance and a swift market entry by Q2-2022.
The compostable cling film Nature Fresh for automatic packaging has been optimized and tested on the newly developed wrapping machines, 2 Food processor machines for the industrial sector (AUTOMAC DUAL and AUTOMAC INDUSTRIAL), and 1 retail machine. The food processor machines have been developed, tested and optimized and are now in commercialization phase. The first 3 prototypes of the retail machine have been manufactured, tested and optimized and now the Retail NF machine (which will be marketed as ARYA) is in the 0 series design phase. In this second period, end user field trials have been conducted on the 3 different wrapping machines to verify their optimization.
To date, the productions of Nature Fresh film and Food processor wrappers are among the scheduled standard activity of Gruppo Fabbri while the Retail wrapper is in finalization.
Regarding the development of the scale, transportation and application unit of the Retail NF machine, main work has been to identify and test compostable labels on their performance, compared to conventional labels. Within this phase the adhesion force, pull out strength and the printing quality of compostable labels have been tested and documented and a final specification of compostable labels has been created.
All the transportation units have been designed to bring products from the automatic weighing system with scale to the automatic wrapping machine using Nature Fresh compostable film to pack products. The scale and scale interface have been designed Including all electronics interfaces and approval processes for electronics and MID (EU weighing & measuring approval). The application units have been designed to place up to 2 top and 1bottom label(s) on product packages, including all electronic interfaces and software programming.
An important effort has been done to prepare specification of prototypes and components as well as mounting guidelines, so any team can properly work with the machines.
The consortium has also worked on marketing concept to promote the EU project and its result named compostable film Nature Fresh and wrapping machines including retail with labelling and weighing system, using available media (web pages, Facebook, LinkedIn, YouTube, ESPERA blog, packaging specialized journals, attendance to exhibitions and fairs…). Market analysis, trend scanning, pricing analysis and governmental regulation have been deeply checked with regards to compostable packaging material. We aim to continue implementing effective marketing & communication actions, exploiting our IP and commercial strategy as well, to let Nature Fresh be widely known and adopted as one of the crucial solutions to the issue of plastic waste.
It has also been important the assessment of the European regulatory landscape related to compostability and food packaging, identification and execution of the laboratory tests for the Nature Fresh packaging solution, as well as the analysis of the criteria to assess the sustainability of food packaging and assessment of the environmental impact of the final solution
To date, the productions of Nature Fresh film and Food processor wrappers are among the scheduled standard activity of Gruppo Fabbri while the Retail wrapper is in finalization.
Regarding the development of the scale, transportation and application unit of the Retail NF machine, main work has been to identify and test compostable labels on their performance, compared to conventional labels. Within this phase the adhesion force, pull out strength and the printing quality of compostable labels have been tested and documented and a final specification of compostable labels has been created.
All the transportation units have been designed to bring products from the automatic weighing system with scale to the automatic wrapping machine using Nature Fresh compostable film to pack products. The scale and scale interface have been designed Including all electronics interfaces and approval processes for electronics and MID (EU weighing & measuring approval). The application units have been designed to place up to 2 top and 1bottom label(s) on product packages, including all electronic interfaces and software programming.
An important effort has been done to prepare specification of prototypes and components as well as mounting guidelines, so any team can properly work with the machines.
The consortium has also worked on marketing concept to promote the EU project and its result named compostable film Nature Fresh and wrapping machines including retail with labelling and weighing system, using available media (web pages, Facebook, LinkedIn, YouTube, ESPERA blog, packaging specialized journals, attendance to exhibitions and fairs…). Market analysis, trend scanning, pricing analysis and governmental regulation have been deeply checked with regards to compostable packaging material. We aim to continue implementing effective marketing & communication actions, exploiting our IP and commercial strategy as well, to let Nature Fresh be widely known and adopted as one of the crucial solutions to the issue of plastic waste.
It has also been important the assessment of the European regulatory landscape related to compostability and food packaging, identification and execution of the laboratory tests for the Nature Fresh packaging solution, as well as the analysis of the criteria to assess the sustainability of food packaging and assessment of the environmental impact of the final solution
According to the ‘A European Strategy for Plastics in a Circular Economy’ document, there is a broad demand for a packaging film 100% recyclable or completely biologically decomposed, summarizing a need for a totally compostable wrapping packaging solution along with easy-to-use and maintain, cost effective packaging machines. Nature Fresh has proven to be that full solution thanks to the combination of compostable labels and film packaging, it offers a fully compostable approach. The Nature Fresh solution delivers direct environmental benefit, assisting in meeting sustainability initiatives. We have strengthened smart, innovative and sustainable plastic packaging, bringing growth and jobs to Europe and cutting EU’s greenhouse gas emissions. Fabbri Group is the manufacturer of the compostable film and the automatic wrapping machines, TEIXPAC is the distribution partner in Spain and ESPERA is the contract manufacturer and supplier of the compostable labels and of the weighing, printing and application system. This supply chain arrangement ensures the consortium partners to get benefits from the Project. In addition, 48 new jobs could be created in the consortium. Once the technology has demonstrated its environmental impacts, we are confident of attracting customers at a global scale.
Nature Fresh packaging solution is a compostable film developed to respond the demands for packaging materials with minimal impact on the environment. Nature Fresh combines its biodegradability characteristics with its protective properties, thus helping to reduce food waste. Nature Fresh packaging solution can be discarded and recycled together with its organic content. That is a great advantage over conventional plastic packaging. Moreover, the results of the LCA study carried out show that the Nature Fresh solution contributes effectively to preserving the environment, preserving resources, and minimizing waste, scoring well on environmental, economic, and social metrics.
From its launch, Nature Fresh film has been produced in hundreds of tonnes and tens of thousands of film reels, with millions of packages brought to market. Also, within a year of project Nature Fresh and compostable label solution was tested in a wide range of applications. The results show a perfect performance regarding printability, adhesion and pullout force compared to conventional labels. The promotion of the compostable labels has started and key customers and opinion leaders can be already targeted
Nature Fresh packaging solution is a compostable film developed to respond the demands for packaging materials with minimal impact on the environment. Nature Fresh combines its biodegradability characteristics with its protective properties, thus helping to reduce food waste. Nature Fresh packaging solution can be discarded and recycled together with its organic content. That is a great advantage over conventional plastic packaging. Moreover, the results of the LCA study carried out show that the Nature Fresh solution contributes effectively to preserving the environment, preserving resources, and minimizing waste, scoring well on environmental, economic, and social metrics.
From its launch, Nature Fresh film has been produced in hundreds of tonnes and tens of thousands of film reels, with millions of packages brought to market. Also, within a year of project Nature Fresh and compostable label solution was tested in a wide range of applications. The results show a perfect performance regarding printability, adhesion and pullout force compared to conventional labels. The promotion of the compostable labels has started and key customers and opinion leaders can be already targeted