AlgiPack: Alginate-based films for packaging

The AlgiPack project aimed to develop flexible, biodegradable, and home-compostable packaging films and coatings from Norwegian cultivated brown algae, offering a sustainable alternative to fossil-based plastic packaging. Addressing current challenges such as high cost, poor water vapor barriers and weak mechanical properties of available alternatives, the project has leveraged innovations combining graphene and cellulose fibers to improve performance and reduce costs of seaweed-based bioplastics and biomaterials. The project efforts have targeted flexible film applications in the food packaging and protective films for non-food industries, specifically developing two different packaging designs: 1) multilayer barrier coatings on paper/cardboard and 2) composite films including cellulose and graphene fillers. The main results obtained during the project are the following: 1. Material Innovation: using nanocellulose we observed limited changes in mechanical properties, and sensitivity to water vapor. Based on these results we started to explore the use of the seaweed fibers for paper production. Seaweed was pre-processed to get a fibrous rich biomass which was mixed with traditional wood pulp, with content ranging from 20 to 70%. Prototypes of grease proof paper coated with alginate formulations and rigid cardboard have been successfully fabricated. 2. Process Optimization: Within this project we were capable of optimizing extraction of alginate form different seaweed biomasses as well as setting the principles for lab scale processes for seaweed paper production setting the base for larger scale cost-efficient biorefinery methods. Extraction process parameters such as time and temperature have been adjusted and optimized to the specific biomass used. 3 Product Validation: Final lab prototypes were fabricated, these have been showcased in several industry events and have been shared also with relevant companies interested in the product at an industrial level.

The findings of this project have provided very valuable insights on the potential of seaweed specifically for paper production, especially taking into account the current transition of conventional packaging to more sustainable alternatives in which most companies are shifting to cellulose based materials. The results of the project have allowed the technology to reach TRL 5 unlocking the potential to further work on scalability of the production process to reach commercial readiness in the near future. This is also in line with new regulation (EU) 2025/40 on packaging and packaging waste, which will enter into force on 11 February 2025 and apply from 12 August 2026, and thus can provide a solution for companies searching for alternatives to conventional plastic packaging.

The annual global production of fossil plastic is over 360 million tons. Around 50% stems from packaging material, and <20 % is currently recycled. There is thus a strong need for biodegradable alternatives that can replace fossil-based plastics. The goal of AlgiPack is to develop flexible home-compostable biobased plastic films and coatings based on Norwegian cultivated brown algae as an alternative to fossil-based plastic used for packaging. Despite their great potential as conventional plastic replacement, algae-based bioplastics still present some technological limitations such as a low water vapor barrier and weak mechanical properties, that are hindering their large-scale utilization in the packaging sector. AlgiPack will address these shortcomings by implementing graphene and cellulose fibers in seaweed based polymeric films. Two specific packaging applications will be developed: 1) Multilayer barrier coatings for paper/cardboard food packaging applications such as food wraps and trays. The laminated structure will include a graphene layer to enhance the gas and water barrier properties and an outer compostable alginate layer serving as a grease barrier. 2) Translucent composite films using an innovative dispersion method of functionalized graphene in combination with cellulose fibrils into alginate for non-food contact packaging applications such as protective bags for the cosmetic, fashion and electronic industries. The project owner, B'ZEOS, is a Norwegian company developing sustainable packaging based on seaweed. Project partner Tor Group AS is an environmental tech company with expertise in graphene and biopolymers. Project partner Seaweed Solutions cultivates sugar and winged kelp, which will be used as raw materials. Research partners SINTEF and RISE PFI will contribute leading expertise on seaweed processing and fibre-based materials. Together, the consortium will meet the increasing demand for more sustainable packaging materials.