BE-UP: Industrial adoption of biodegradable polymers for sustainable packaging applications

The BE-UP project is working to accelerate the transition to sustainable packaging using biodegradable and recyclable materials. For this purpose, new synthesis routes for aliphatic-aromatic biopolyesters with high renewable content are being used combining innovative catalysts and additives. They will be blended with other biopolymers and organic and inorganic additives via advanced compounding modelling tools. The project also focuses on processability, adapting the materials to key packaging production techniques such as blown film and cast film extrusion, injection molding, and thermoforming, and manufacturing prototypes (TRL7) to validate their performance. 

The results will support the development of circular design tools and guidelines, aligned with the Safe and Sustainable by Design (SSbD) framework, and help improve standardization for material testing and packaging labelling. 

BE-UP is expected to replace more than 50,000 tons of non-biodegradable plastics by 2032, achieving annual savings of over 120,000 tons CO₂ eq, thereby driving real progress toward more sustainable packaging. 

Context

The BE-UP project responds to the needs outlined in the EU Plastics Strategy, the Single-Use Plastics Directive, and the Circular Economy Action Plan, which promote replacing fossil-based plastics by more sustainable materials to reduce contamination and environmental risks. Despite their potential, the adoption of biodegradable biopolymers in high-performance packaging remains limited due to performance and processability challenges, particularly in techniques such as blown film extrusion, cast film extrusion, injection molding and thermoforming. 

Be-UP aims to develop innovative aliphatic-aromatic biopolyesters, combined with commercial biopolymers, catalysts, and additives, optimized through advanced digital modelling tools, to create sustainable and recyclable packaging materials. These materials will be evaluated for processability, performance, biodegradability, and recyclability, while also generating tools and guidelines for circular design aligned with the Safe and Sustainable by Design (SSbD) framework and supporting standardization for packaging testing and labelling. Furthermore, biodegradation modelling tools will be used to develop a biodegradation mathematical model taking into account laboratory test data and real environments both under controlled conditions and in open environment.  

Summary and objectives

The BE-UP project aims to develop a new generation of biodegradable materials for packaging applications, based on advanced biopolyesters and aligned with the principles of sustainability and the circular economy. 

To achieve this, new biopolymers will be synthesized and optimized, materials with improved properties for industrial processing will be formulated, and biodegradable packaging prototypes will be validated at a pre-industrial scale. In addition, their biodegradability in different environments and their safety will be assessed following the Safe and Sustainable by Design (SSbD) approach, in order to facilitate their future industrial adoption and maximize their environmental and socioeconomic impact. 

Specific Objectives

O1. Synthesis and polymerization of new biopolyesters
Develop innovative aliphatic-aromatic biopolyesters with improved technical properties compared to fossil-based polymers, using non-toxic catalysts and advanced digital modelling, while optimizing biodegradability and processability. 

O2. Development of biodegradable packaging materials
Formulate biopolymer blends with additives and commercial materials to enhance thermal, mechanical, and barrier properties, ensuring compatibility with industrial packaging processes. 

O3. Scale-up of packaging prototypes
Validate six biodegradable packaging prototypes at pre-industrial scale, demonstrating energy efficiency, reduced friction, and costs comparable to conventional plastics. 

O4. Assessment and modelling of biodegradability
Evaluate biodegradability in lab and real-world environments, using advanced modelling to predict degradation pathways and ensure complete decomposition under relevant conditions. 

O5. Implementation of the SSbD framework
Assess the technical, environmental, and human safety of materials and packaging following the Safe and Sustainable by Design (SSbD) approach, including recyclability and greenhouse gas reduction. 

O6. Maximizing long-term impact and value
Promote standardization, labelling, stakeholder engagement, and commercial adoption of circular business models through workshops, policy recommendations, scientific dissemination, and participation in international events. 

Consortium

The BE-UP consortium consists of:

• INSTITUTO TECNOLÓGICO DEL EMBALAJE, TRANSPORTE Y LOGÍSTICA (ITENE), Spain – Coordinator 

• HYBRID CATALYSIS BV (HYB), Netherlands 

• PARTICULA GROUP DRUSTVO S OGRANICENOM ODGOVORNOSCU ZA ISTRAZIVANJE RAZVOJ I PROIZVODNJU (PART), Croatia 

• ISOTECH LTD (ISO), Cyprus 

• EUROPEAN BIOPLASTICS EV (EUBP), Germany 

• Polinivo (POLIN), Belgium 

• IDENER RESEARCH & DEVELOPMENT AGRUPACIÓN DE INTERÉS ECONÓMICO (IDE), Spain 

• NORMEC OWS (OWS), Belgium 

• CEBIMAT LAB SL (CEB), Spain 

• INNOTECH COEXPAN-EMSUR SL (INNO), Spain 

• NOVAMONT SPA (NVMT), Italy 

• POLYMERIS (POLY), France 

• IMERYS TALC EUROPE (IME), France 

• FAKULTETA ZA TEHNOLOGIJO POLIMEROV (FTPO), Slovenia 

• ASOCIACIÓN ESPAÑOLA DE NORMALIZACIÓN (UNE), Spain 

• Aptar France SAS (APT), France 

• UNIVERSITÀ DEGLI STUDI DI TRIESTE (UNITS), Italy 

In WP8, ITENE coordinates the overall project management, ensuring scientific quality, timely delivery of results, and monitoring of consortium progress. This includes contractual and financial management, communication among partners, and reporting to the European Commission, guaranteeing that all deliverables meet the required quality standards.