PULPFICTION is a project focused on the development and optimization of 100% recyclable and biodegradable molded cellulose packaging with enhanced functional properties, designed to provide new alternatives to plastic packaging in sectors such as food, cosmetics, and electronics, thereby promoting sustainability and resource efficiency.

Context

The rigid packaging market is experiencing strong growth, driven by the need for sustainable solutions in response to European regulations requiring that all packaging be reusable or recyclable by 2030. Currently, much rigid packaging is made of multilayer plastics that make it difficult to recycle, posing a major environmental challenge.

Molded cellulose emerges as a promising alternative, as it is 100% recyclable, biodegradable, and offers good cushioning properties, thermal stability, and mechanical strength. However, there are significant limitations to its application, particularly in the food sector, regarding barrier properties (moisture, oils, gases) and sealing capacity.

PULPFICTION presents itself as an innovative response to these challenges. The project aims to optimize the manufacturing process of molded cellulose, reducing resource use such as water and energy consumption, and incorporating natural additives and functional coatings that improve the barrier properties of the packaging without compromising its ultimate recyclability.

In addition, the project involves active collaboration with Valencian companies in key sectors and aligns with the Valencian Community’s circular economy and sustainability strategy (S3-CV). Thus, prototypes will be validated under real-world conditions in the food, cosmetics, and electronics sectors, ensuring their technical and commercial viability.

Summary & Objectives

PULPFICTION aims to develop rigid molded cellulose packaging solutions that are fully recyclable and offer advanced functional properties for the food sector as primary packaging (trays for fresh produce and ready-to-eat foods), the cosmetics sector (secondary packaging for single-use cosmetic containers), and the electronics sector (protective components for electronic products), in the latter two cases, considered as secondary packaging.

The project proposes a comprehensive innovation by optimizing pulp formulations to improve resource efficiency, using natural additives, and applying barrier coatings through lamination with compostable films or spraying to enhance barrier properties without compromising recyclability.

Thus, the project seeks to achieve the following specific results:

• Cellulose pulp formulation portfolio: Develop formulations using virgin or recycled fibers, depending on whether they are intended for food contact or not, and enhance their properties through the use of bio-based additives to optimize molding and reduce water and energy consumption.
• Functional spray coatings: Optimize the formulation of spray-applied barrier coatings on three-dimensional tray-type packaging, improving resistance to moisture, fats, and gases without compromising recyclability.
• Coated food packaging: Apply spray-applied coatings to packaging for fresh products and IV and V-range foods, ensuring adequate barrier properties for preservation and sealing.

In this regard, we are working on the development of packaging solutions tailored to different sectors:

1. Food packaging with liner films: Laminating with compostable films, minimizing thickness to improve barrier properties without compromising recyclability in packaging for fresh products and ready-to-eat and pre-prepared foods.
2. Cosmetics packaging: Developing formulations with coating technologies that prevent rancidity or degradation of the product for cosmetics packaging, as well as secondary packaging that protects cosmetic products.
   • • Protective packaging for electronics and cosmetics: Design solutions with sufficient structural strength and barrier properties to replace secondary plastic packaging in small appliances and cosmetics.
     • Safety and recyclability validation: Verify the food safety of the final prototypes in accordance with Royal Decree 10/2011, the safety of prototypes intended for cosmetics, as well as the recyclability of the developed packaging.
3. Packaging eco-design and logistics validation: Design and validate packaging for electronic and cosmetic products by optimizing protection, material usage, and performance during transport.