Making the Food Packaging Greener: The BIO-SUSHY’s PFAS-free Coatings
Have you ever wondered about the packaging in which your food comes?
In this latest article, we look at how we can make food packaging safer and environmentally friendly through the BIO-SUSHY project.
The Need for Sustainable Food Packaging
We have all heard and know about plastic pollution and its harmful effects on our environment due to landfilling and incineration. When it comes to food packaging, plastic waste, non-biodegradable materials, and the use of harmful chemicals such as PFAS have further contributed to pollution and human health risks.
However, the recent Plastic Packaging Waste Regulation set new targets to reduce packaging pollution and help build a circular economy for packaging. In parallel the change is driven by initiatives like our EU-funded project, which meets stricter regulations and implementation of Safe and Sustainable by Design principles from an early R&D material and process design phase. To bring such novel coating solutions closer to the market, the BIO-SUSHY project also addresses consumer preferences for safer and environmentally friendly solutions for future food packaging.
To face these challenges, BIO-SUSHY is developing bio-based thermoplastic powder coatings for paper substrates.
Meet BIO-SUSHY’s Answer to Food Packaging
BIO-SUSHY develops bio-based thermoplastic powder coatings derived from renewable resources such as plant and nature-based polymers. These materials are processed into fine powders that can be applied to various surfaces using electrostatic spray techniques. The result is a durable, uniform coating that offers excellent grease resistance and water-repellent barrier properties against moisture and oil.
These coatings protect our food just as well as traditional packaging, and the key features of this technology include:
- High grease & water-resistant performance comparable to traditional petroleum and PFAS-based coatings
- Reduced carbon footprint due to renewable sourcing
- Biodegradability and repulping during paper recycling addressing end-of-life concerns
Figure 1: The process of making organic powder coatings involves several steps. First, the raw materials are mixed to create a uniform blend. This blend is then ground into a fine powder, which is sprayed onto the surface to be coated. Finally, the coated surface is heated and pressed to cure the coating and make it stick.
Why Should You Care?
- Earth-friendly: These coatings come from renewable sources (like lignin).
- Safe to use: The BIO-SUSHY team is making sure that these novel coatings meet all safety standards by implementing an innovative, safe-and-sustainable approach from their material and process design phase (read more about the safe-and-sustainable by design, SSbD, framework here).
- Keeps food fresh: It protects against moisture and grease, keeping your snacks crispy and fresh.
Applications in the Food Packaging Value Chain
The versatility of bio-based thermoplastic powder coatings makes them suitable for a wide range of food packaging applications:
- Flexible packaging: Films and pouches for snacks and dried goods
- Paper-based packaging: Coated paperboard for takeaway containers
These coatings enhance shelf life, maintain food quality, and provide an effective barrier against contaminants while being environmentally friendly.
In the case of BIO-SUSHY, the main focus and validation of our developed coatings is related to food tray packaging made of paper and cellulosic sheets/mats. The 3D shape of the final package will be provided via thermoforming.
Regulatory Considerations
The food packaging industry is heavily regulated to ensure consumer safety. BIO-SUSHY’s bio-based coatings are developed with these regulations in mind, adhering to strict EU standards for food contact materials.
To delineate a roadmap for certification, the food trays developed using thermoplastic powder technology will be tested on several aspects, such as recyclability, compostability, migration, and liquid and fat resistance.
What’s Next?
Bio-based thermoplastic powder coatings can play a significant role in a shift towards safer and more sustainable packaging. Future developments may include:
- Expansion into another food packaging application segments addressing coatings formulation adoption to extrusion coating
- Enhanced barrier properties for extended shelf life
- Incorporation of active ingredients for smart packaging
So, next time you unpack your groceries or enjoy comfort food from a fast-food chain, remember: the future of food packaging is getting safer and greener, thanks to innovative projects like BIO-SUSHY.
