the biobased packaging revolution

Textile industry has issues regarding microfibre shedding during use phase and washing. This problem is emphasized when fabrics are based on recycled materials. Finish coating treatments assist to mitigate this problem.  The result consists of a biobased formulation which reduced the number of microfibers released from an (r-)PET or (r-)PLA fabric and is not harmful to organisms in the environment. The developed product is a  new alternative on the market and anticipates current issues in the textile sector regarding microfibre release.

Currently, numerous packaging materials are composed of several components to achieve the desired shelf-life properties. These co-extruded products, such as PA/PE or PET/PE films which are much used for example for modified atmosphere packaging (MAP) or to provide puncture resistance of vacuum food packaging, are currently recycled as blends with inferior mechanical properties even after compatibilization.

Within PRESERVE, the goal is to produce bio-based microfibrillar reinforced materials of PE/PET and PE/PA coming from recycling streams. As a result, intimate blending enables the creation of materials with customized properties that outperform existing homopolymers. The microfibrillar reinforcement is an interesting approach for the upcycling of mixed polymer waste, with tailored applications.

Within PRESERVE, a new method for the elimination of bio-based coatings has been developed. With the use of an enzymatic soap, whey-based coating from PE, PET, cardboard and PLA and also from multilayer has been removed. A complete delamination process has been developed in four steps: shreedding, washing, separation, and pelletizing. This method will facilitate  the separation of multilayer packaging containing the PRESERVE protein coating, thereby enabling the recycling and recovery of biobased materials in an efficient and straightforward manner. Furthermore, the method is readily replicable.

In PRESERVE, we have developed a demonstrator that proves that industrial recycling of discarded bio-based plastic packaging (PLA) can lead to a new, attractive and reproduceable non-food product application that may be of value to the companies that produce and sell the initial products with their packaging and communicate their circular ambitions. We also look at reducing the release of microplastics with bio-based coatings.

These methods allow for the closing the loop of material use, especially that of bio-based plastics, in order to reduce the CO2 footprint. In this way, recycled materials can be reused in ways that will also allow not only the reduction of plastic waste, but also the purposeful reuse of recycled materials. For companies putting plastic packaging in the market, it would be a great opportunity to reuse their packaging for marketing purposes.

Metallization of packaging layers contributes to enhance barrier properties, resulting in an almost impermeable layer. The downside is that upon application on polymer films, it interferes with the recycling of said polymer films resulting in colour distortion. The combination of the protein coating and the metallization would simplify the delamination process and would show ultra-high oxygen barrier properties.

This innovation addresses a critical challenge in polymer recycling by ensuring that metallization applied to a protein coating does not interfere with recycling processes.When the protein coating is enzymatically degraded for delamination, the metallization ends up in the wash water. Consequently, the metallization will not affect the polymer recycling. Metallizing protein-based coatings usually bears the risk of damages occurring in the protein layer in form of cracks and holes due to the process of metallization in the high vacuum chamber. Despite previous concerns, no visible nor measurable defects in the WPI-layer on the substrate could be detected and excellent barrier properties could be achieved. Investigated substrates were films of PLA, PET, and PE.

Eco-design of packaging involves a concept where the materials used have less impact on the environment in each stage of the packaging life. This means using bio-based raw materials, biodegradable (if it is possible) or recyclable Secondary Raw Materials (SRM) and less microplastic release. With this method, more eco-friendly packaging solutions will be available which actually have a low environmental impact, less microplastic release and an end-life closing the loop (SRM or biodegradable) with an independence from fossil-based raw materials.

For the recyclable solutions, an application for these SRMs will also be found. Packaging concepts and the use of SRM must usually be adapted. The pollution on the planet is increasing every day and this eco-packaging concept will help to reduce the CO2 footprint, microplastic release and the reuse of the resources. One of the risks related to this solution is the discontinuous availability of resources, quality of SRM and possible pollution/contamination in collected bio-based plastic.