At the start of the project, the focus was on optimizing Plantics resin formulations for molded paper products. Key considerations were enhancing paper barrier properties, making it resistant to water and oil, and ensuring product durability. The resin's applications spanned various needs, and successful scaling of resin synthesis was rapidly achieved. Trial products were produced and tested out in different markets, indicating market readiness and demonstrating that the product performance requirements are met. In addition, preliminary contracts with suppliers and customers were being drafted.
In RP2 the European market landscape for moulded paper products were subject to heavy change. The COVID-19 pandemic propelled demand for paper products, coupled with the transition from plastic to paper packaging. This shift strained the production capacity for molded paper products, leading to supplier disruptions and greenhouse closures. Consequently, the project timeline was extended. Despite delays and tough market conditions, we managed to produce and sell 300k plant pots in Germany. This attests to market readiness. Experience from semi-lab production enriched our multi-purpose pilot plant's design. Additionally, we've acquired expertise in consistent large-scale resin and plant pot production.
Due to shortages of recycled paper and moulder paper products in Europe, the plant pots were temporarily purchased from China. New market trials were started in this 4th reporting period in greenhouses, growing different plants under different conditions. A business developer was hired to promote the Plantics’ plant pots, which are promoted under the brand “DOPA plant pots”. In the meantime, tooling design for mould production with a European supplier for paper plant pots was started. Besides plant pots, we started two development projects to introduce our material for (indirect) food contact packaging with two potential partners. Furthermore, the first large investment of the multipurpose pilot production installation was installed and successfully commissioned.
During RP5, the second large investment of the pilot production installation was successfully commissioned. With this installation we have nearly doubled our potential production capacity for standard plant pots. The production capacity was used to maintain a stable stock of plant pots ready for sale. One large cultivation test was completely monitored from growth to transportation to sales in shops, which proved to be a huge success and has also led to a larger follow-up order in the following reporting period.
In the final reporting period, the flexible pilot production installation was fully completed and is used for full-time production. The increased production output is achieved by applying iterations to the design based on learnings in production. With the increased output we maintain a stable stock of plant pots ready to supply the demand by sales. Emphasizing sustainable partnerships, the project steered toward the retail sector, manifesting in increased sales from repeat customers. Notably, the European tooling design from the European supplier persisted as a technical challenge, impeding large-scale production realization.
