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Report

Teaser, summary, work performed and final results

Periodic Reporting for period 1 - SULACHANGE (Microplastic-free Sulapac-material challenges plastic)

Teaser

Summary

The extensive use of plastic in packaging is a growing global challenge. Over 30% of the 78 million tons produced annually ends up polluting our environment. There is not a great alternative for the plastic yet in the mass market: biodegradable bioplastics degrade too slowly and non-biodegradable bioplastics pollute the world with microplastic.
Finnish SME Sulapac has created the most sustainable packaging solution in the world. It is 100% biodegradable and contains 0% microplastics. SulapacÂ® has all the benefits of plastic, but without the waste problem. The renewable woodbased material has a low carbon footprint, yet it is similar to plastic in terms of price, formability and functionality.
SulapacÂ® is a fast biodegrading water, oil and oxygen resistant material solution. It is suitable for mass manufacturing of rigid and flexible packaging such as jars and tubes. It can also be used for light weight packaging. Sulapac is a real
alternative to plastics used in high-volume cosmetics and food industries.
The aim of the SULACHANGE project is to finalise our product offering to capture the full potential of our unique material and prepare for global scale market introduction. We will optimise our recipe and barrier coatings for high volume cosmetic and food industries, apply for required certificates, do customer pilots and create a licensing model. As a result of the project, the company will grow to annual revenues of â‚¬90 million within a few years.

Work performed

WP1: Product development
Identification, development and characterization of two barrier materials that are suitable for emulsions has been achieved. Their compliance with water-based emulsion has been shown. In the field of optimization of the fibre content, a totally new material was launched: the Sulapac Universal material. The functionality of this material was proven in a trial campaign with over 60 participants around the world. Cosmetics package compliance and food contact certifications have been acquired for all Sulapac materials. Knowledge of testing practices and implementation of them to the product development process have been achieved.

WP2: Pilots
Piloting has been successfully realized with two well-known companies: Chanel, France (chanel.com) and Fazer, Finland (fazer.com). The Chanel product is a cosmetics article, whereas a food package was developed for Fazer. The success is demonstrated with a projected launch of the former product early in 2020, and the latter having already been launched in December.
In addition, contact with various food-package manufacturers, as well as companies in other areas, has been achieved. A Polish company, MikoPac (mikopac.com), has shown the proof-of concept of thin-walled rigid package. This case has shown the potential of our new Universal materialâ€™s in specific applications and brought insight to the further development of flexier material, and materials that can be shaped in thermoforming.

WP3: Commercialisation and dissemination
During 12/2018 and 12/2019 we managed to increase the amount of our traffic from 20-30.000 to 90-100.000 unique visitors per year. Focus was mostly on content marketing and PR.We are following closely the development of new standards relevant to Sulapac, and our clients, and participate in the discussions of the working groups preparing those. We constantly take the regulatory development into account in our R&D work.
We also want to highlight that we are committed to continuous learning and improvement and believe that cooperation is key for the best possible outcome. We also warmly welcome open discussion on our approaches.

Final results

At begin of the project, the suitability of prototype packages that were made of Sulapac material had been demonstrated in operating environment (TRL7) for oil and wax-based material. The mechanical properties had been verified and stability of the package had been verified to be at least 12 months.
During the course of the project, the package manufacturing process with Sulapac rigid material for oily and wax contents has reached TRL9. In addition, the material has been shown suitable for dry foodstuff, as well as short-term water and alcohol-based beverages according EU 10/2011 food-contact regulations. A notable example is the launch of chocolate package with the well-known and traditional food company Fazer with a package that fulfils their high-scrutiny organoleptic testing in December 2019.
To ensure the supply chain strategy and smooth implementation to existing injection molding process, a Sulapac Trial campaign was launched. For this, a Sulapac Material Data Sheet and Processing Advice, Mold Selection Guide, and Safety Data Sheet, were established. According to the feedback of altogether 60 participants in the campaign, 35% were satisfied with the material, whereas 60% urged for a flexier recipe. As an example, a light-weight package provider expressed deep interest in replacing current plastics in ice-cream container. Many learnings were received how to further improve the material, and the Data Sheet and Mold Guide. Several converters are now waiting to get more material for mass production tests and then replacing conventional plastic in certain applications.
Simultaneously, the entire Order-Delivery process was established and refined, including placement of orders, Working Instruction for material delivery and acceptance criteria upon receipt, storage, and handling of finished goods, an in addition, training the personnel. For contractors making the compound (Sulapac granules for converters), careful selection criteria have been established regarding available capacity, flexibility, required equipment, and location. The companies have been audited and trained to handle the raw materials needed for Sulapac material production according to the requirements set by Sulapac.
To support the go-to market, a service has been established. Sulapac gives training to brands/converters about the material, its key features and how to communicate about it to their customers. Sulapac has created many types of assets that customers can add to different parts of their customer journey. Moreover, Technical support person is available 24/5 to support on any technical questions and to support on the production ramp-up and trials, e.g. with injection molding machinery and raw material handling.
The progress thus far has proven the proof-of concept of launching a new product category of sustainable material made of renewable sources, is microplastics free and 100% biodegradable, and verifying functionality of three business models: Selling ready-made products, joint development agreements, and material sales.
The results may be extrapolated to establishment of the potential of sustainable alternatives that fulfil requirements of the demanding food package industry by providing a recyclable alternative. Sulapac is also attractive when compared other bio-based materials, as it contains up to 80% (v/v) of wood that is derived from wood industry side streams, making Sulapac material considerably faster degrading, and more cost efficient.