Project R-12306

REPAC² - Functional & recyclable coated paper packaging for food products (Research)

In WP1, coatings and coated papers were inventoried. Task 1 involved sending a survey to 87 companies via email, with distribution through LinkedIn, newsletters, and websites. Information was received from 16 companies on 77 products (coating + coated paper). This product inventory was supplemented throughout the project as a second task, resulting in an online inventory that was made accessible in January '24. The inventory is searchable on product specifications (e.g., barrier properties, grammage, paper types,…) and used by companies to make first selection on suitable coated papers for packaging solutions. The tool is also approachable as a first interface by non-member companies, who are further guided by experts and brought into contact with suppliers. As a third task, after 5 months, a shortlist of 14 coated papers and 2 coatings was compiled, taking into account the ultimate goal of obtaining 16 papers with various barrier properties. This selection was discussed with participating companies on May 10, '22, during a first international meeting with guidance groups from Flanders, Germany, and Poland. The papers were coded for confidentiality reasons, with short descriptions for all materials. The white paper, which was included as a deliverable in WP1, was expanded with more information than just the technical data from WP1 and consequently became a general practical guide for the industry to implement coated paper in primary food packaging. This white paper was released in January '24, with an additional online event on January 30th discussing this. In WP2, it was necessary in the first task to apply the two selected coatings on paper. As a second task, all 16 coated papers were tested according to the pre-established scheme of the CORNET application. This resulted in an extensive results matrix with measurements of mainly the sealing properties, barrier properties, and mechanical properties. These results were discussed during a second international meeting on October 20, '22. The results were also added to the online inventory, the white paper, and briefly summarized for the respective materials in the case study report. The methods were demonstrated during the first part of the REPAC² workshop on September 5, '23 in Diepenbeek. WP3 investigated the sustainable potential of the coated papers. In task 1, a method was validated to determine the technical recyclability of paper, based on the harmonized laboratory protocol released by CEPI (version October 2022) as part of the 4-evergreen project. This method was discussed with participating companies during the second international meeting at the end of '22. A pilot line for paper recycling with new testing equipment has consequently been installed, including repulping, screening and handsheet making in combination with an evaluation protocol based on microscopic evaluation and NIR spectroscopy. As a second task, the materials from the shortlist were tested according to this method, and the results were presented during the end meeting on December 12, '23. A ranking was based on the recyclability score, which is influenced by fibre yield, visual inspection score and sheet adhesion score. However, the results showed that the recyclability assessment and scoring was very strict and negative score for one criterion can highly be altered by the other criterion. Therefore, it is advisable to carefully consider each of the parameters with priority on fibre yield versus presence of impurities in recycled handsheets. The separate aspects were clearly demonstrated and priority screening results were discussed within the guidance group, indicating differences between dispersion coatings, laminated coatings and metallized papers. The method for recyclability tests was also demonstrated during the second part of the REPAC² workshop on October 5, '23. A very good impression on validation of the evaluation protocol was obtained through collective evaluation of the results with member-companies of the guidance group, indicating good reliability of the visual observations. Member companies were updated on the future prospects of the recyclability protocol with permanently changing evaluation criteria (becoming more strict), and the evolution into expected binding regulation in 2024/2025, which remains highly challenging for adaptation. The recyclability data was finally added to the online inventory and the white paper, and briefly summarized for the respective materials in the case study report. In the next four tasks of this work package, the environmental impact of packaging concepts from coated paper for specific foods was determined. For each of these combinations, a comparison was also made with the current packaging material, which in many cases consisted of plastics. During the second international meeting at the end of '22, the approach was discussed, to ultimately discuss the results during the third international meeting on June 20, '23 and at the end meeting. The most striking result of this detailed analysis is that the environmental impact was largely dependent on the food and much less on the packaging material, both in paper and plastic packaging. The conducted impact analyses are summarily described in the white paper. The more detailed studies for each of the cases can be found in the case study report. In WP4, food companies and packaging suppliers were brought together to exchange information and facilitate implementation. In task 1, two online matchmaking sessions were organized between food and packaging companies from the REPAC² consortium to define the 6 case studies. For each of these cases, a coated paper was selected from the REPAC² shortlist for a specific food item. The resulting combinations were then studied in detail in WP 6. As the second task of WP4, an international matchmaking event was organized on November 23, 2023, for both REPAC² members and non-members. This event in Brussels aimed to connect participants in one day with different international partners (Poland, Germany, Belgium) to expand their network and business. During the morning session of the event, the REPAC² project was presented, and each company had the opportunity to briefly introduce itself during an introductory round. Furthermore, companies that wished could present their most recent innovation or biggest challenge in the field of coated paper food packaging to the audience. The afternoon was dedicated to targeted matchmaking sessions where food and packaging companies could get to know each other during a 20-minute conversation. These meetings were pre-arranged by the organization based on the needs and offers described by the participants on their registration form. Immediately after the event, an evaluation form was sent out to the participants from the 19 different companies that were present. The responses from the 15 respondents (response rate = 78.94%) indicate that the participants were satisfied with: i) the practical organization – timing, 100% satisfied & location, 100% satisfied; ii) the content of the event – morning session, 100% satisfied and quality of matchmaking sessions, 92.3% satisfied. As an area for improvement, the respondents indicated a desire for more input in determining the matches to further improve quality. Finally, 100% of the respondents reported making new contacts thanks to the matchmaking event, both during the morning session, lunch, and afternoon session. Of these new contacts, 93.3% estimated that they would lead to new business opportunities. In WP5, the shelf life of packaged food items was simulated. First, data on the current packaging, spoilage mechanisms and shelf life were collected from WP2 and discussions with the food producers. Where indicated, water sorption and oxygen consumption characteristics of foods were analysed experimentally and supplemented with literature data if necessary. Then, shelf life simulations were carried out for the packaged product in relevant storage scenarios comparing the conventional packaging with the proposed alternatives. The results were presented during the third international meeting in May '23. The final simulation results and validation with actual shelf life tests were discussed during the end meeting. The results were documented in the case study report and summarized in the white paper, indicating that coated paper is generally a suitable alternative in primary food packaging, unless there are serious packaging defects that compromise the barrier function. WP6 involved implementation activities in the form of 10 case studies. Task 1 involved conducting tests on the packaging lines of companies to evaluate the coated paper in practical conditions, determining additional properties in the development of new paper used during one of the six detailed case studies, and conducting a SWOT analysis with participants to identify advantages and disadvantages. These aspects were documented together with relevant aspects from WP2, 3, 4, and 5 in the case study report. In addition to this broad approach, four additional cases were carried out. One of these cases focused on comparing leak tightness between plastic and paper materials, resulting in the need for an extensive parameter study for certain packaging concepts. In addition, practical insights were documented in two interviews with companies with the necessary expertise in the implementation of coated paper. These insights highlighted important adjustments and strategies needed for successful implementation: the use of serrated bars, lowering the speed of the packaging line, minimizing contact with sharp objects, using soft parts, and increasing sealing time were highlighted as crucial elements to make implementation smooth. Finally, a last case was carried out to study a grease-resistant paper and determine whether its implementation could be extended to other applications. During the end meeting, all cases were extensively discussed with the participants. WP7 focuses on disseminating project outcomes. In addition to various publications, workshops, and webinars, there are three key deliverables made available: An online inventory (https://www.sirris.be/en/database_coated_paper), a white paper serving as a guide for using recyclable coated paper in food packaging (https://portal.sirris.be/repac2-whitepaper), and a detailed case study report (https://docs.google.com/forms/d/e/1FAIpQLSczpjaDLOv8-ASJpcPcB1Lh3TmuIDOhBgqM4bAuIfaennLbOQ/viewform).

01 January 2022 - 31 December 2023