RenewPACK: Demonstration of an Innovative Renewable Barrier Material for Sustainable Food Packaging

PROJECT DESCRIPTION

BACKGROUND

The EU food packaging industry uses some 247 000 tonnes/yr of thin aluminium foil. When used in multilayer constructions, such as food trays, this material is very difficult to separate and recycle, meaning that, for the purposes of the food industry, significant quantities of new aluminium must be produced from scratch. Food packaging can also have a negative environmental impact through the use of high-barrier plastics, such as EVOH (ethylene vinyl alcohol copolymer) and PVdC (a synthetic plastic containing chlorine). Some 120 000 tonnes/yr of these materials are produced in the EU, generating 132 000 tonnes of CO2 emissions, if the material is recovered by incineration. PVdC can, moreover, give rise to emissions of the highly toxic substance, dioxin, when incinerated.

OBJECTIVES

The main objective of the RenewPACK project is to demonstrate the suitability of a new patented material, Xylophane, as a barrier material in food packaging. Xylophane is based on xylan, which is a natural polysaccharide derived from agricultural by-products (grain husks) and is therefore renewable and biodegradable. Specific aims of the project are:

To demonstrate the production process of xylan which involves a highly innovative process step membrane filtration; and

To demonstrate the many possible recycling options for Xylophane and its advantages over existing materials i.e. incineration, composting and ability to be re-pulped.

The project envisages the construction of a prototype pilot plant that will serve as a model for future full-scale plants in Europe. Since the technology and production process could be licensed to target groups within the agricultural sector and the paper chemical industry if the proposed project is successful, it would allow local agricultural communities to diversify their income streams, thereby strengthening them in the event of a downturn in the agricultural sector.

Expected results: The main result will be the demonstration of how non-renewable and very energy intensive packaging materials can be substituted with a new, highly innovative and patented material that is renewable and biodegradable. The project will have the following quantitative results:

Energy savings: 80-90% reduction of energy consumption for the production of Xylophane in comparison aluminium foil, which correlates to 52-84 GWh for the pilot plant;

Reduction of CO2 emissions: A 100% reduction of fossil fuel consumption in comparison with EVOH will reduce the emission of new CO2 to the loop by 100%. This correlates to 400-1 000 tonnes of fossil fuels and 1 200-3 300 tonnes of CO2 respectively for the pilot plant. The project has the potential to actually be CO2 negative given that the raw material is biodegradable and the waste produced will be transformed into biogas;

Reduction of toxic material: 100% reduction of dioxin emissions in comparison with PvdC; and

The worlds first production of xylan on a large scale: 12-15 tonnes per week of xylan will be produced.

RESULTS

The Coordinating Beneficiary Xylophane AB has declared bankruptcy on 31/08/16 and therefore the implementation of the project has been suspended.