Grantee Research Project Results
Final Report: Fully Compostable Packaging Film From Microfibrillated Cellulose
EPA Contract Number: 68HERC22C0025Title: Fully Compostable Packaging Film From Microfibrillated Cellulose
Investigators: Csuka, Ella
Small Business: Ecotune, Inc.
EPA Contact: Richards, April
Phase: I
Project Period: December 1, 2021 through May 31, 2022
Project Amount: $100,000
RFA: Small Business Innovation Research (SBIR) Phase I (2022) RFA Text | Recipients Lists
Research Category: Small Business Innovation Research (SBIR)
Description:
Ecotune is a renewable materials technology startup developing high-performance, bio-based materials for applications including packaging. In this EPA SBIR Phase I research project, Ecotune developed and tested compostable packaging films made from microfibrillated cellulose, an emerging sustainable material with significant potential to be used in the next generation of biodegradable packaging. Over 100 billion tons of cellulose are made annually by plants on Earth, and it is the most abundant solid natural material on the planet. Highly fibrillated celluloses have remarkable strength, surface area, and low weight, which make them the ideal raw material for flexible packaging films.
Cellulose is bio-based, biodegradable, and non-toxic, whereas current petrochemical-based plastics are significant contributors to greenhouse gas emissions, toxic chemical consumption, and global microplastic pollution in the environment. Approximately 18 billion pounds of plastic enters the ocean each year, with about 40% of all plastic produced being used for packaging. Flexible films are vital for packaging, but current multi-layered plastic films are often single-use and non-recyclable. Biodegradable fiber-based packaging films can be composted into fiber-rich compost to return nutrients back to the soil.
Significant challenges exist for nanocellulose-based materials, including high cost of production, specifically resulting from the energy and time involved in manufacturing processes, as well as the limitations in the barrier properties, sealability, and processability of microfibrillated cellulose films. During this project, Ecotune developed novel chemical formulations, coating formulations, and dispersion processes to advance the technical and commercial feasibility of nanocellulose-based packaging materials.
Summary/Accomplishments (Outputs/Outcomes):
This project successfully developed compostable packaging films made of cellulose, the most abundant organic compound on Earth. The microfibrillated cellulose-based films meet project objectives of 1) synthesizing 100% bio-based films achieving the required performance metrics 2) developing a low environmental impact material with capacity for both home and industrial composting, and 3) creating a scalable, cost-effective process with high potential for commercial manufacturing.
Over the course of the Phase I project period, Ecotune developed and tested microfibrillated cellulose films for use as flexible packaging films, characterizing a range of material properties including physical, mechanical, barrier, optical, structural, and end-of-life. All chemicals utilized in the R&D process were renewable, bio-based, and non-toxic, and selected in accordance with "green chemistry" principles. Correspondingly, the laboratory-scale synthesis process did not involve any hazardous chemicals or toxic wastes. The quality and properties of the packaging films were systematically tested according to international material testing standards, achieving the key technical objectives set forward.
Conclusions:
Novel processing methods and parameters were developed to enhance physical properties, production speed, and sustainability metrics. The technical data generated in this project demonstrate the feasibility of making and using microfibrillated cellulose films as compostable packaging materials, at the laboratory scale and beyond.
Ecotune aims to develop sustainable materials for a circular economy by providing material innovations that are readily scalable from bench to pilot to commercial production. Therefore, scalability was evaluated and optimized at every step in the R&D process throughout the duration of this Phase I project. This project successfully demonstrated the potential of fiber-based packaging films utilizing novel nanocelluloses to replace plastic-based materials. Biodegradable packaging is estimated to reach a market size of $22-128 billion in the next few years, growing at a faster rate than any type of plastic packaging. Global markets for plastics are estimated at $235 billion, and flexible plastics account for over half of the plastics market at $144 billion. The speed at which renewable materials are developed and adopted at the global scale will have a significant impact on the environment, human health, and the planet.
The perspectives, information and conclusions conveyed in research project abstracts, progress reports, final reports, journal abstracts and journal publications convey the viewpoints of the principal investigator and may not represent the views and policies of ORD and EPA. Conclusions drawn by the principal investigators have not been reviewed by the Agency.