The National Centre for Research and Development

  Project title

Functional and recycled coated paper packaging for food products 

  Name of Beneficiary/Beneficiaries

Beneficiary: Natureef Association

Contractor: West Pomeranian University of Technology in Szczecin

  Name of programme

International programmes

  Competition

CORNET 31

  Project value

PLN 1,415,472.57

  Funding value

PLN 1,322,233.04

  Project delivery period

from 1 January 2022 to 31 December 2023

Meet our team

Photos from the meeting of the companies participating in the REPAC project.

See the results of our work

As part of the project, a White Paper was created, detailing the results of the project and a database of coated papers.

In addition, we prepared two press articles which we sent to the media.

What problem does our project solve?

Packaging plays a key role in the food supply chain, protecting quality, ensuring safety and extending the shelf life of food products. Every day, the food packaging industry is faced with the choice of the most suitable material for packaging specific food products. Additionally, the question is raised about which material is more environmentally friendly and whether the packaging material used is recyclable.

Paper and cardboard seem to be ideal packaging materials that meet the requirements of recyclability thanks to the renewable origin of the cellulose fibres, their high stiffness and low weight. On the other hand, paper has no inherent properties to protect the quality and durability of packaged food products. The performance of the paper must be adapted through barrier coatings that provide protection against water, gas permeability or retain aromas. Today, numerous food packaging coating materials made of paper and cardboard are available on the market. Traditionally, laminated plastic films have been applied to paper, but in recent years alternative coatings based on aqueous polymer dispersions have been developed. However, it is not always clear whether these coating materials meet the desired properties and are suitable for the intended application.

To support the industry in the rapid implementation of paper- and board-based coated materials that have good barrier properties in contact with food and are also recyclable in accordance with current legislation, seven European research partners have joined together in the Cornet project: REPAC2: Recyclability and functionality of coated paper and board for food packaging. The results of the project in all relevant aspects concerning these materials, their assessment in terms of technical functionality, sustainability, the industry's view on industrial implementation and answers to frequently asked questions are summarised in the REPAC 2 white paper available at: https://natureef.pl/cornet-repac/. In addition, there are two sources of information created to support companies in the use of paper-coated packaging: a case study report detailing the 10 industrial cases that were carried out, taking into account all those analysed, and a database containing information on commercially available coatings or coated paper for food packaging. The database can be found here.

Who will benefit from the project's results?

The REPAC² project leads to important innovations by expanding the knowledge base, but also by providing examples of concrete changes and innovations in the companies involved.

• In response to the question in the final survey as to which specific project results are being applied, companies provided different answers. Based on these answers, it is clear that the type of knowledge applied strongly depends on the target group. The listed results can lead to several innovations/implementations. Here is an overview:
• coating manufacturer: A case study on fruit roulades provided valuable insights that contributed to a better understanding of product ageing and its environmental impact. This can lead to the development of better coating solutions that are more durable and can guarantee a longer product life.
• coated paper manufacturer: The changed perception and implementation of paper-based packaging is important knowledge that will be applied. Knowledge about perception can lead to adjustments in how metallised paper is marketed. Knowledge about implementation can prompt improvements in the production process to, for example, improve the puncture resistance for paper or better match its barrier properties to specific food products.
• food supplier: With knowledge of paper recyclability, the right supplier can more easily be found for a sustainable packaging strategy, which can improve sustainable image and reduce carbon footprint.
• raw material producer: Comparing different barrier structures opens up opportunities to develop innovative materials that better meet the requirements of modern food packaging.
• packaging supplier: Understanding the applications of coated paper for direct food contact can lead to innovative packaging solutions for fresh food, with improved sustainability and safety.
• coated paper manufacturer: Focusing on the barrier properties of coated paper can lead to the development of innovative paper that better protects against moisture, gases and liquids.

In addition to the information provided by the companies in the survey, the participation in a matchmaking meeting (organised, among others, by Natureef, for food and packaging companies) at the NCRD headquarters in Brussels, is considered an important step in knowledge transfer and the promotion of cooperation, which can lead to concrete changes and improvements in the products and processes of the participating companies.

Finally, the following changes, formulated specifically for each target group, can be considered as potential outcomes of the project that will be applicable to Polish companies:

Food companies

- Efficient packaging process

• Sealing
  • In spite of the insulating thermal properties of paper, sealing can be carried out at low temperatures if appropriate coatings and suitable settings and tools are used → Faster sealing due to reduced initiation temperature
  • Need to use appropriate settings and tools → More sealed packages
• Barrier
  • With a better understanding of the barrier properties of paper and its impact on food safety, it is possible to adapt packaging to different types of food, ensuring better shelf life and freshness of products → Longer shelf life
  • Development of new materials and technologies to increase the durability of packaging and improve its ability to protect food → Higher quality packaging, less waste
• Mechanical properties
  • Research into the strength of paper can lead to the production of more robust packaging that better protects content from damage in transport and storage → Less waste, less waste

- Sustainable packaging

• Recycling
  • The use of large quantities of metallised paper in packaging can lead to difficulties in recycling packaging → Development of recycling methods for packaging containing metallised paper
  • Research into the recycling of metallised paper can lead to the development of efficient recycling processes that minimise material and energy losses → Sustainable recycling practices
• Biodegradable coating materials
  • Exploration of innovative biodegradable coating materials can lead to the development of packaging that is more environmentally friendly while providing the required protective properties → Less waste, less environmental impact

 

Packaging companies

- Innovative technologies

• Research into new coating materials and production technologies can lead to the development of innovative packaging solutions that meet increasing customer demands for durability, performance and functionality → More competitiveness in the market, more profit opportunities
• Implementation of innovative research and testing methods (e.g. numerical modelling, computer simulation) can reduce product development time and R&D costs → Faster time to market for innovative products, greater manufacturing flexibility

- Sustainable practices

• The use of metallised paper and other materials with increased durability in packaging can help reduce the amount of materials and waste used and increase production efficiency → Sustainable production, less waste
• Development and implementation of biodegradable coating materials can reduce the environmental impact of packaging, an important aspect for customers and consumers → Improved corporate image, increased customer loyalty

 

Suppliers of raw materials

- Innovative products

• Development of new packaging materials with improved durability and functionality can open up new markets and increase demand for raw materials such as coated paper, barrier films and protective coatings → More sales opportunities, higher profits
• Implementation of innovative production technologies (e.g. nanotechnology, biotechnology) can lead to the production of more advanced and competitive packaging materials that meet increasing market demands → Better competitiveness in the market, greater production flexibility

- Sustainable production

• Development of methods to process and recycle packaging raw materials can reduce the negative environmental impact of production and increase resource efficiency → Sustainable production, less waste, less environmental burden

 

All in all, the REPAC² project leads to a broader knowledge base, but also by providing examples of concrete changes and innovations in the companies involved, it makes it possible to better understand project results and their implementation in companies.

What was the biggest challenge for us in implementing the project?

Project implementation was smooth.