Researchers in Finland have developed a new generation of fully cellulose-based films and coatings that could help the packaging industry reduce its dependence on fossil-based plastics while meeting increasingly stringent sustainability regulations. Developed through the Films for Future (F3) project by VTT Technical Research Centre of Finland and LUT University, the material platform combines high-performance packaging functionality with recyclability and biodegradability.

As regulations such as the EU Packaging and Packaging Waste Regulation (PPWR) place greater emphasis on recyclability, material composition and lifecycle impacts, the need for alternatives to conventional plastic packaging continues to grow. The F3 project addresses this challenge by creating transparent cellulose films and barrier coatings that can perform similarly to plastics while supporting circular end-of-life pathways.

Processing Cellulose as a Polymer

A key innovation of the project lies in the ability to process cellulose as a polymer rather than as a fibre. This approach enables the production of transparent films with mechanical strength and barrier properties comparable to those of conventional plastic packaging materials.

The cellulose films are inherently biodegradable, while the coatings have been engineered to remain compatible with fibre-based recycling systems and, where required, biodegradation routes. Unlike many biobased alternatives, the materials aim to avoid the common trade-off between performance and sustainability.

Researchers have already demonstrated compatibility with established packaging conversion techniques, including thermoforming, which could facilitate integration into existing manufacturing infrastructure without requiring major process changes.

High Barrier Performance for Food Packaging

The technology has been successfully demonstrated at pilot scale across multiple packaging applications. According to the project partners, the cellulose films achieve oxygen barrier performance with oxygen transmission rates (OTR) below 1 cc/m²/day, comparable to many conventional plastic packaging materials. The coatings provide even stronger oxygen barrier properties, with OTR values below 0.2 cc/m²/day, while also delivering grease resistance rated at KIT 12.

These characteristics make the materials particularly suitable for applications such as dry food packaging, bakery products and fibre-based packaging systems that require transparent barrier layers.

Beyond Plastic Replacement

While the immediate focus is on replacing plastic packaging, the researchers see broader opportunities for the material platform. Future developments may include antimicrobial and antioxidant functionalities, as well as responsive packaging systems capable of reacting to changes in humidity, gas composition or pH. Such features could support the growing field of active and intelligent packaging.

The technology may also find applications beyond packaging, including medical materials, electronics and advanced functional coatings, highlighting the versatility of cellulose as a renewable material resource.

Following the completion of the F3 project in March 2026, the consortium is now focusing on scaling the technology towards commercial implementation, supported by a network of 34 industrial partners.

Source & photos: VTT Technical Research Centre of Finland