Only 31% of plastic is currently recycled and plastic packaging still have a deficient end of life. Thus, improvements are needed to provide cost effective solutions with high bio-based contents and suitable performances for demanding packaging applications, with a consumption of 19M ton/year, while still achieving compostability in mild conditions. Using sustainably sourced comonomers, additives and fillers to formulate novel PLA copolymers and compounds, the BIOnTOP project will deliver recyclable-by-design cost competitive packaging solutions that can be mechanically recycled, industrially/home composted or even suitable for anaerobic digestion. Moreover, the barrier properties of delivered bio-packaging trays, films and derived packaging, will be enhanced using removable protein-based coatings and a novel fatty acid grafting technology to decrease permeability and compete with fossil packaging. In the field of textile packaging , most used coatings are not bio-based and of different nature from the coated fibres, making material or organic recycling extremely difficult. New PLA coatings or fatty grafting will allow reprocessing without significant loss of properties. BIOnTOP packaging, based on >85% renewable resources, will be compatible with a broad range of packaging applications’ requirements but also multiple end of Life options. Our materials will be biodegradable in home composting conditions but also recyclable for multiple use secondary packaging. Based on new circular bioeconomy value chains, BIOnTOP will generate growth for EU bioplastics and end users’ industries in the food and personal care sectors with potential in many fields: BIOnTOP production is estimated to reach close to 9.6 Mton per year by 2030, overall leading to €40 M turnover and 170 new jobs. All in all, reducing the environmental footprint of plastics, our new bio-based packaging will have a significant positive social and environmental impact.

TORNADO project aims to contribute to the transition to a safe circular economy by influencing how products should be designed, produced, used or treated at their end-of-life. New organic and hybrid free-toxic coatings with water and oil repellence following Safe and Sustainable by Design (SSbD) criteria will be developed. The novel proposed coatings will be PFAS free. TORNADO idea is to research and develop 1) Two new type of functionalized acrylated biomonomers with PDMS and POSS by two different chemical routes (acrylation and direct acrylation). 2) To synthesized and formulate 2 new biobased coatings based on the functionalized biomonomers by two technologies, waterborne organic and hybrid coatings and hybrid sol-gel coatings. Biomonomers and coatings will be scale up in an industrial environment. Coatings will be applied by different industrial processes depending on the industrial field. The two coatings will be validated in industrially relevant environments to obtain a performance at least identical to PFAS coatings in terms of water and oil repellence and tested according to the main textile, packaging and kitchenware specifications and requirements (waterproofness, oxygen barrier and durability, respectively). The improvement in environmental performance and circularity of the new coatings will be assessed through environmental Life Cycle Assessment, Life Cycle Cost, and social Life Cycle Analysis (LCA/LCC/s-LCA) of the proposed new coatings compared to traditionally used hazardous coatings. Computational tools will be developed for efficient interfacing with publicly accessible and accepted QSAR-models to facilitate ease-of-use in-silico prediction of required physiochemical properties, toxicological end-points and degradation.

GRECO aims to demonstrate the life cycle and techno-economic feasibility of greener & safer bioplastics value chains for the food packaging sector, based on a safe and sustainable by design (SSbD) strategy. To this aim, innovative bio-based, biodegradable, and recyclable packaging based on new PLA copolymers, coatings, additives and catalysts accompanied by surface treatments will be produced. Regulatory compliance will be demonstrated while contributions to new or modified standards and proper labelling will be proposed. Digital tools will drive the developments from the simulation and modelling scopes, and social sciences and humanities (SSH) will provide relevant information related to social perception and acceptance. All of them will pave the way to facilitate the introduction of the new products into the packaging market sector and our society. Contribution to the Plastics Strategy, the Single-use Plastics Directive (SUP) and the EU Circular Economy Action plan (CEAP) will be ensured. GRECO will introduce the food packaging industry to groundbreaking bio-based, SSbD, and fully circular PLA-based materials, that meet diverse application needs. These alternatives aim to replace fossil-based, complex, and multimaterial structures prevalent in the industry, improving packaging end-of-life through biodegradation in various environments like industrial and home compostability, anaerobic, marine, and soil. The design will ensure recyclability and avoiding of chemical interactions that hinder overall biodegradation.

Within Be-UP project new synthesis and processing routes will be developed for novel aliphatic-aromatic biopolyesters with increased renewable content using biobased building blocks (e.g 1,4 bio-BDO), alongside innovative catalysts and additives. These components will be optimized through advanced digital modelling tools, based on Kinetic Monte Carlo (kMC) models, for synthesis and polymerization. These biopolyesters will be blended with commercial biopolymers (e.g., PLA, PBAT, and PHA), biobased chain extenders, and mineral fillers to create bioplastic packaging materials. The design of these blends will employ advanced compounding modelling tools, supported by techniques like screw design and inline rheology measurements, to achieve the target technical performance, sustainability and biodegradation goals using multi-objective function evaluation. Processability will be also a key factor, with a focus on the primary production techniques used in the packaging industry, namely, blown film extrusion, injection moulding and thermoforming. A set of packaging products’ prototypes (TRL7) will be manufactured to validate the developed materials. The biodegradability of these novel products will be assessed in different End-of-life (EoL) scenarios, including open environments and controlled conditions, thus making possible to fill the gap between laboratory conditions and real end-of-life behaviour of these materials. Additionally, the recyclability of the new products will be evaluated. The data and conclusions of these assessments will be useful for: i) the development of guidelines and tools for circular design contributing to the adoption of the Safe and Sustainable by Design (SSbD) Framework; ii) contributing to improve the standardization framework for testing and labelling of materials and packaging products. Be-UP is expected to replace more than 50,000 tonnes in 2032 of non-biodegradable plastics leading to savings of over 120,000 CO2 eq tonnes yearly.