H2020 CelluWiz Project: Development of processes for a recyclable and compostable multi-layer cellulose material for packaging

Type Project
Status Filled
Execution 2019 -2022
Assigned Budget 2.841.875,00 €
Scope Europeo
Autonomous community Comunitat Valenciana
Main source of financing Horizon 2020
Project website https://doi.org/10.3030/838056

Description

Packaging is important for the transport and protection of food and products. Proper packaging ensures safe transport, protects food, and provides important marketing information. However, plastic packaging is harmful to the environment. The EU-funded CelluWiz project will develop two advanced processes that allow the production of environmentally friendly packaging materials. The project is supported by five partners from four EU countries specializing in real-time operational (RTO) systems and packaging. The new materials are based on microfibrillated celluloses (MFCs) and will be recyclable and compostable, while ensuring the protection of food and products. CelluWiz will demonstrate its environmental benefits and efficient adaptability in the value chain. Small pilot devices will demonstrate the competitiveness of CelluWiz materials.

Description of activities

CelluWiz has enabled the development of two technologies for pilot-scale production of 100% cellulosic packaging materials with excellent barrier properties for food packaging. The chromatograph-grafted laminated board reels produced on a pilot scale enabled the production of three proof-of-concept models (clamshells, cups, and trays). Compostable, recyclable, and biodegradable in the marine environment and in industrial compost, these products exhibit excellent barrier properties. This project lays the groundwork for a new generation of 100% cellulosic packaging materials as an alternative to existing plastic or complex materials. At the end of the project, the following significant scientific and technological achievements can be highlighted:

From Work Package 2 (WP2): Wet rolled MFC coils with a specific oil barrier were delivered for subsequent work packages for the production of the PoCs. The operating window of the small pilot machine was determined and described in terms of the influence of MFC concentration, MFC grade, machine speed, feed rate, filtration medium, vacuum boxes, replication and drying.

Homogeneity and dryness content before replication were slightly improved with replication on wet board and vacuum boxes with larger suction area respectively.
Analysis of 3D images obtained with X-ray microtomography allowed the determination of the thickness of the MFC layers and their contact surface with the board.
Analysis of the mechanical behavior of MFC films under biaxial tensile loading showed that MFC films induce a pronounced driving stress to bend the wet laminated board upon drying.

From WP3:

A methodology has been implemented to investigate grafting in the z direction that allows the localization of grafted fractions.
Samples with ultra-high graft densities have been obtained after developing a new technology to open MFC films.
Grafting MFC films at ultra-high grafting densities led to water barrier performances far beyond the target specifications for all PoCs.
A power law relationship has been demonstrated between graft densities and water barrier performances, allowing the prediction of target modification values for a given requirement.

The chromatogenic process has been improved by adding steam boxes before and after grafting which have significantly increased the grafting efficiency and mechanical properties of the WP4 MFC laminate films.

The removal of coarse elements from an MFC suspension by sieving through a fine-wire opening has been tested in a laboratory-scale device.

Deflocculation in an MFC suspension by screening in a semi-industrial sized pressure screening pilot plant at a concentration up to 2.7% has been repeated and shown to be stable Del WP5.

The steam box after grafting improves convertibility due to higher moisture content.

The proofs of concept were produced, tested, and delivered according to plan.

Not all KPIs for barrier performance were met, however, real-life testing of the demonstrators showed excellent to good performance of the WP6.

All three PoCs are compatible with conventional industrial packaging recycling, and therefore comply with the EN13430 standard "Requirements for packaging recoverable by materials recycling." The recycling rate is 100% for the clamshell and tray, and 97% for the cup.

The environmental performance of the CelluWiz cup, from a cradle-to-grave perspective, improves compared to the paper/PE cup in all impact categories, with a reduction ranging from 18% to 82%.

A 3D eco-efficiency analysis shows that the CelluWiz cup is the most sustainable option compared to the paper/PE cup and the PS plastic cup analyzed as benchmarks.

In terms of suitability for food contact, the tested materials meet the requirements applicable to paper and cardboard according to BfR Recommendation XXXVI, although intentionally added substances must be authorized for such use, even if no specific migration of these substances is detected under the conditions of use studied.

Contextual description

To achieve the overall objective of Celluwiz, four specific objectives have been defined:

Developing the wet lamination process: This glueless process assembles paper and board with a layer of microfibrillated cellulose (MFC), creating a laminated cellulose material. This MFC layer provides rigidity, lightness, and a barrier to air, grease, and oxygen. Upon completion of the project, the pilot MFC wet lamination machine will be able to produce up to 80 kg of wet-laminated board per day with 20 g/m² MFC.
Developing the chromatogenic coating and grafting process for MFC layers: This process is an ultra-fast and efficient solvent-free chemical grafting process capable of transforming hydrophilic cellulosic materials into hydrophobic ones. The chromatogenic pilot process can now process 500 kg of wet-laminated board per day. On a standard wet-laminated board, the graft density is 35 mg/m², compared to 19 mg/m² at the start of the project. Building on the work developed to open up the MFC structure, a density of 500 mg/m² was achieved on a pilot scale.
Produce 3 proofs of concept of all-cellulose materials: Clamshells, Cups and Trays: 100 pieces of each PoC were produced.
Demonstrate the environmental benefits of innovative processes and materials and their easy integration into the value chain, by carrying out Life Cycle Analysis (LCA) and Life Cycle Costing (LCC) with accurate and relevant data: When comparing the CelluWiz Cup with the recycled paper/PE cup, the CelluWiz Cup can reduce the carbon footprint by 40% and if we compare the recycled CelluWiz Cup with the incinerated PS plastic cup, the reduction is 75%, therefore the KPI is met.

Objectives

The overall objective of CelluWiz is to develop two processes capable of producing a fully cellulose packaging material that offers a competitive alternative to existing multi-layer plastic materials or multi-materials used in the packaging sector, while being renewable, recyclable/upcycled in the waste paper value chain, and biodegradable. These two innovative processes, the MFC wet lamination process and the chromatogenesis process, were combined to produce three proofs of concept: clamshell packaging, cups, and trays. The environmental benefits of the innovative processes and materials, and their easy integration into the value chain, were assessed by performing Life Cycle Assessments (LCA) and Life Cycle Costing (LCC) with accurate and relevant data.

Coordinators