Biocomposite films made from biopolymers and antioxidants extracted from wheat straw and mango peels can replace petroleum-based packaging materials, such as low-density polyethylene plastic film, for food packaging, says Stellenbosch University Department of Process Engineering postdoctoral fellow and chemical engineer Dr Lindleen Mugwagwa.
Wheat straw and mango peels are normally disposed of in landfills or used as animal feed, but can provide feedstock polymers and antioxidants to produce renewable, biodegradable and nontoxic active food packaging.
Active food packaging has the ability to respond to temperature and time changes in food storage and could help keep products fresher for longer. This is one of the main findings of her recent doctoral study.
As part of her study, Mugwagwa developed and optimised processes for extracting polymers and antioxidants. She then combined the polymers and antioxidants to make a food packaging material and tested the stability of the biocomposite films when in contact with food, as well as their potential to release antioxidants into packaged food over time.
Low-density polyethylene film, a commonly used plastic, was used as a benchmark.
The properties of polymers and antioxidants in wheat straw and mango peels can be tailor-made during extraction to suit their application in food packaging, says Mugwagwa, adding that the polymers and antioxidants can be extracted simultaneously from the same feedstock without affecting their use in food packaging.
“The bio-based films that I developed were capable of releasing more antioxidants into food over a short period of time when compared to low-density polyethylene plastic. This suggests they can be a replacement for perishables food packaging.
“The release of antioxidants into food by packaging material is becoming an important aspect to consider when choosing packaging material. Packaging material capable of releasing antioxidants into food in response to storage conditions have the potential to increase the shelf life of products because the released antioxidants act upon free radicals and microorganisms, which may develop when food is improperly stored or stored for longer periods.”
The polymers are cheap, sustainable and biodegradable and can be used in the development of food packaging, as well as presenting methods for recovering natural antioxidants and their application as additives to food packaging material. These natural antioxidants have the potential to replace artificial antioxidants in packaging material. Biorefineries and the food packaging industry, as well as farmers and consumers, will benefit from the research, she says.
Mugwagwa’s study was conducted under the supervision of Stellenbosch University Department of Process Engineering professor Annie Chimphango, with the financial support from the Organisation for Women in Science for the Developing World, the Swedish International Development Cooperation Agency (SIDA), the National Research Foundation of South Africa, the Department of Science and Innovation and the Council for Scientific and Industrial Research Waste Road Map, and Stellenbosch University Department of Process Engineering.
Developed centuries ago, paper has a fascinating history as it has been through the mill – literally and figuratively – in terms of what it is made from, says paper and pulp industry association the Paper Manufacturers Association of South Africa (PAMSA).
It also has many interesting side stories such as the not well known story of paper storing carbon – which makes it good for the planet.
Even when planted trees are harvested for their wood – for paper, timber construction, packaging and tissue – the carbon remains locked up in the wood fibres and stays there for the lifecycle of those products. It is just one of the reasons paper recycling is important as it keeps the carbon locked up longer.
“To understand why paper and wood products are vital to a lower carbon footprint, we can borrow from Nobel Prize-winning physicist Richard Feynman’s assertion that trees don’t grow from the ground, they grow from the air,” says PAMSA executive director Jane Molony.
The photosynthesis process involves plants absorbing sunlight and carbon dioxide to make food. Trees take in carbon dioxide from the air, and water from the ground – which also came from the air at some point – and convert this into growth (trunks, roots and leaves). Oxygen is then returned to the atmosphere, meaning that this carbon cycle is why trees of all kinds are such a vital part of keeping our planet regulated, offsetting greenhouse-gas emissions and mitigating climate change, the association explains.
“In South Africa, trees can be divided into two groups – indigenous trees in natural forests and commercially and sustainably farmed trees in plantations. The latter were introduced some 100 years ago to protect natural forests, by providing farmed wood for productive purposes,” adds Molony.
Plantation trees are essentially crops that are planted and replanted in rotations, with only 9% of the total tree count being harvested in any given year. This means that there are always trees growing, at different stages of maturity, and these trees are contributing to the carbon cycle.
New Chapters for Wood
As the paper sector finds ways to diversify in the face of digitisation and reduced printing and writing paper demand, chemists and chemical engineers are increasingly discovering the “wonder of wood”.
Wood is made up of cellulose, hemicellulose, lignin, sugars and extracts. The properties of these elements make them suitable ingredients in countless, low-carbon products.
For example, dissolving wood pulp, a purified form of cellulose, is suitable for chemical conversion into a range of products – it is spun into viscose and lyocell textile fibres for use in fashion and decorating textiles, cast into a film or regenerated into a sponge.
It is extremely versatile as it can also bind active medicinal ingredients or vitamins into palatable tablets, stabilise emulsions or increase viscosity – which is why it is added to low-fat yoghurt and lipstick.
Nanocellulose – tiny cellulose nanofibres – can be used in food supplements and edible packaging, or even as a composite for screens on electronic devices.
Further, paper packaging manufacturers are exploring its use in weight reduction for paperboard without compromising strength and performance. The substance can also be applied as a recycling-friendly barrier coating instead of plastic.
By extracting more value from a tree, less goes to waste, Molony notes. “This opens the sector up to make even more meaningful contributions to sustainable product development and the circular economy.”
And by growing more trees and making innovative things from them, she concludes that the general quality of life can improve, which would make the world more sustainable.
Dental product manufacturer Colgate on April 22 launched its recyclable toothpaste tube in South Africa to coincide with Earth Day.
Made from number two high-density polyethylene (HDPE), the new tubes will contain one of three Colgate Naturals toothpaste, including its charcoal, hemp seed oil and aloe vera variants of toothpaste.
Colgate claims that, historically, toothpaste tubes have been made of materials that cannot be recycled, including certain plastics and aluminium foil.
However, its new tubes, which were launched in other regions in 2020, have been developed to contain nine layers, using two grades of HDPE plastic and which can be recycled by companies capable of handling HDPE materials.
Colgate South Africa GM Francois Falls says that, while the new recyclable tubes are a Colgate project, the outcomes from it should be for the broader toothpaste manufacturing community. In this regard, he says Colgate plans to openly share its innovation with other companies. “Our dream is to have all tubes, not only toothpaste, be recycled in practise and at scale.”
Colgate also has plans to move all its toothpaste products into recyclable tubes in the future.
It further states that it is working with third-party recyclers to establish recycling capacity for its new tubes.
Your packaging strategy and processes can significantly impact your ability to maintain a smooth and efficient supply chain.
1. Collect relevant product data at the outset. Get all relevant product information—size and weight, shipping mode, and safety requirements—up front to help develop and execute an efficient, compliant packaging strategy. This information will help ensure you use the appropriate packaging and train your employees properly.
2. Know each step and material needs. The packaging process and the materials needed can vary by product. Know each step of the operation, the materials needed (from box type to inserts to seals), and how to properly use those materials to ensure personnel have the right items when and where they need them and won’t have to halt operations to get unexpected items or ask questions.
3. Learn the regulations. Stay up to date on packaging and labeling requirements for each item you ship—from materials to warning labels to employee training. Understand how they impact your operations.
4. Make packaging part of budgeting decisions. Understand your budget from the beginning to design the best packaging for your needs without having to make last-minute design or material changes to stay within budget.
5. Work withan expert. A partner that specializes in areas relevant to your business—custom design or hazardous materials for example—can help you design packaging that fits your needs while considering ease of use, regulatory compliance, and other factors.
6. Minimize waste. Understand specific packaging, labeling, and testing requirements for the items you ship to better identify opportunities to eliminate waste. Reducing unnecessary steps and overpacking will help streamline operations while reducing costs.
7. Eliminate last-minute decisions. Know your products and their packaging requirements up front, communicate relevant information with internal personnel and supply chain partners, and proactively plan for potential disruptions.
8. Use the right tools for the job. The complexity of the packaging process can vary depending on the product you ship—especially if it is classified as “dangerous” and therefore highly regulated. Consider what tools could streamline the operation—for example, assembly/closure instructions or shipping software to automate processes.
9. Leverage advanced packaging. Some solutions have been engineered so the box provides adequate protection and meets regulations without the need for gel packs, heavy liners, pellets, or fillers. These advanced solutions reduce the need for additional protective materials.
10. Stay innovative and think outside the box. Don’t do things just because that’s how you’ve always done them. Refine packaging strategies and tap innovative solutions to further improve efficiency. Whether it’s using specialty materials instead of standard cardboard boxes to ship high-risk items or simply evaluating the steps in your procedures, changes big or small can make a huge difference.
SOURCE: Bill Barger, senior packaging product manager, Labelmaster
ThePackHub’s latest report tackles packaging innovation trends with a global view. The recently published Global Packaging Trends Compendium 2021 details more than 550 packaging innovations and is grouped into nine trend sections. The first to be tackled in the report is ‘Naturally Done’. Paul Jenkins, Managing Director, ThePackHub, looks at some of the highlights.
The Naturally Done trend covers the drive for the use of more natural substrates. These new material developments aim to find potential alternatives to plastic or discover ways to utilize naturally-based by-products for packaging use.
There are many compostable, biodegradable and bio-based packaging initiatives coming to market worldwide. Many of the initiatives listed are still in development and not yet on supermarket shelves. The R&D projects may be two or three years away or may not even reach the end consumer due to lack of funding or not finding a workable commercial solution. Many bio-based materials are being used. Sugar cane continues to be the most popular, but we’re also tracking tomato fibre, whey, chitin, bamboo, mushroom, cacao beans, straw, seaweed, pasta waste and many more.
Without established industrial composting systems in place in most markets, the compostable sector is at a turning point. Mass adoption will only really occur when the infrastructure to deal with the packaging is fully in place. Home compostability is still relatively niche with most consumers not having the space or the will to participate. There are also concerns about compostable and biodegradable packaging contaminating existing recycling waste streams.
Cost may also be a significant barrier, with bio-based packaging often costing a lot more to supply than the price of conventional plastic-based products. It requires a substantial investment for any brand or retailer to employ. We have yet to see many larger company examples introduced. The majority are small challenger brands and startups looking to stand out in the market for what is perceived as a more sustainable point of difference.
The latest in bio-based packaging innovation
Typical of the innovations featured is Dual-ovenable moulded fibre bowls made from sugarcane. Health brand Primal Kitchen is reported to be the first to commercialize a new, dual-ovenable moulded fibre tray based on US-grown sugarcane. Now part of Kraft Heinz, Primal Kitchen’s new line of bowls and skillets is available through retailers such as Thrive Market, Walmart, Whole Foods and Wegmans. The dual-ovenable bowls from Sonoco-owned Natrellis Packaging are made using raw materials sourced from within the US.
Another use of by-products is discarded palm fibres converted into compostable food packaging material. A UAE startup is turning unwanted palm fibres into compostable food packaging materials. The country has a widely abundant local palm leaf resource. Palm Co. has developed a process through which fibre is extracted from the leaves of palm trees. Water and latex is mixed into the fibres where it is then dried and moulded and coated with latex into shape. Latex is a naturally occurring resource that does not affect compostability. The material is estimated to compost in around 90 days.
Elsewhere, Estonian start-up Woola produces compostable bubble wrap from leftover sheep wool – an abundant resources that is usually thrown away. As the quality is not sufficient for fabric production, Woola claims that 90% of sheep wool equating to 153 tonnes is thrown away in Estonia every year. Wool is a natural resource that regenerates every year and it is effectively available for free. Sheep wool’s functional properties ensure that it is shockproof and has thermal insulation (for both heat and cold). It is also able to lock in moisture (up to 37% of its own mass).
US beauty brand Each & Every is making the switch from plastic with the launch of a new sugarcane pack for its line of natural deodorants. The main result of the activity sees a reduction in the company’s carbon footprint for its packaging. Each & Every is introducing sugarcane packaging made from a 100% plant-based and renewable resource, which it says is carbon negative. Sugarcane actually absorbs CO2 as it grows, removing it from the atmosphere. The sugarcane is fermented, distilled and dehydrated to convert it into a packaging material. The packaging can be recycled through kerbside collection.
More to come
The Naturally Done trend is anticipated to remain buoyant beyond 2021. It is likely that brands and retailers will continue to develop ‘natural’ solutions to meet their various 2025 deadlines.
The 2021 Global Packaging Trends Compendium comprises nine new packaging trends. It features a comprehensive assessment of more than 550 packaging innovations. It also includes interviews with 16 industry experts from around the world, featuring packaging experts from the likes of Mars Wrigley, Mondelez, Ocado, as well as Tim Sykes, Brand Director at Packaging Europe.
Coca-Cola’s in-house global design team collaborated with Kenyon Weston on the package redesign.
The new look is clean and minimal, with the redesign seeing the company strip back all the visual clutter from the packaging. These added elements include the red disc and wave line around the can, which has now been removed.
According to the company, its intent with the redesign was to provide a “simple and intuitive navigation system that carries across all Coca-Cola variants, while simultaneously celebrating the Coca-Cola logo”.
Also, as a “visual metaphor to uplift”, the new design raises the Coca-Cola logo to the top of the label.
The updated design will be led by the Coca-Cola Zero Sugar range, which also recently debuted a new recipe – bringing the taste closer to the original variant.
The new design is currently only launched in Europe and Latin America. The global rollout of the new design on the other variants will take place throughout 2021, with a complete conversion of its trademarks expected by 2022.
PEPSI announced a collaboration with the PEEPS Brand, PEPSI x PEEPS a new beverage that combines the taste of PEPSI cola with the PEEPS marshmallow flavor. The PEEPS-inspired design will appear on 7.5-ounce PEPSI mini-cans in bright yellow, pink and blue colorways.
“After what has been a very difficult year, many consumers are looking for new things to smile about. So, to celebrate the start of springtime, Pepsi collaborated with PEEPS to develop a limited batch of its first-ever marshmallow cola. This PEPSI x PEEPS collaboration will be available in three bright colors through a distinctive mini-can design and will most certainly have fans buzzing all season long,” says Todd Kaplan, VP marketing – Pepsi. “We know our consumers love our limited product drops, and we believe that PEPSI x PEEPS will deliver an iconic and delicious pairing that has the potential to become a fan favorite.”
“The PEEPS Brand always finds great joy in teaming up with partners to bring our beloved marshmallow flavor to fans in new and exciting ways, which is why we’re thrilled to collaborate with PEPSI on this limited-edition PEPSI x PEEPS beverage leading up to the Easter holiday,” says PEEPS brand manager Caitlin Servian. “We look forward to seeing how fans express their PEEPSONALITY as part of the #HangingWithMyPEEPS sweepstakes and hope they enjoy this sweet new cola offering.”
PEEPS and PEPSI are also collaborating to bring the collaboration to life with PEEPS dioramas.
US-based consumer products company Tupperware Brands has expanded its ECO+ sustainable product line and announced a partnership with chemical company Eastman.
US-based consumer products company Tupperware Brands has expanded its ECO+ sustainable product line and announced a partnership with chemical company Eastman.
The Lunch-It Containers and Sandwich Keepers will complement the portfolio’s existing products, including the ECO+ Straw Set and ECO+ To-Go Cups.
Launched in 2019, ECO+ products were initially made from a material that used mixed plastic waste.
The line has since incorporated products made from various sustainable, recycled, biobased and environmentally conscious materials.
To further expand the ECO+ range, Tupperware will use Eastman’s Tritan Renew recycled resin.
Tritan Renew is powered by Eastman’s polyester renewal technology, which converts single-use plastic waste into a durable, safe and BPA-free material.
The material uses as much as 50% certified recycled content and can be used to design clear or transparent products.
Tupperware Product Innovation executive vice-president Bill Wright said: “Our efforts to support the next generation of sustainable materials continue to reflect upon our purpose to nurture a better future every day by reducing waste at every step of the product lifecycle.
“I’m honoured today to expand our ECO+ line with new product introductions and our new partnership with Eastman’s Tritan Renew, which allows us to use recycled material in our more transparent designs.
“I know together, we’ll work to reshape what is possible in regards to recycled material.”
Eastman Speciality Plastics vice-president and general manager Scott Ballard said: “Tupperware has been at the forefront of sustainability, even before sustainability was top of mind. The brand is synonymous with bringing durable, reusable plastics into the home to keep food fresh.
“At Eastman, we’re pleased to make molecular recycling a reality and deliver products that reduce consumption, advance the circular economy and create value from waste. Tupperware’s choice of Tritan Renew shows what is possible today, not just years in the future.”
Both this strategic partnership and expansion of the ECO+ range will enhance Tupperware’s No Time to Waste vision, which aims to minimise food and single-use plastic waste through innovation and design.
Under the partnership, Tupperware’s reusable food containers were to be used to support World Central Kitchen in distributing prepared meals at relief sites globally.
UK-based dog food and packaging company Skinner’s CEO Tim Hansell tells Packaging Gateway why sustainability has become a vital factor to consider in the pet food packaging industry and how the national pet food packaging shortage gives evidence to this
The lockdowns designed to curb the Covid-19 coronavirus pandemic have triggered a sharp rise in UK dog ownership, up from 9.9 million per-pandemic to 12 million as of early 2021. Pet food production has risen to meet this new demand, but it has raised questions about the availability and sustainability of its packaging.
The latest data shows that 80% of retailers found that their customers’ demand has grown for sustainable packaging across its products. For any business that is looking to not just retain its current base but grow it, especially in the ever-competitive dog food market, switching to sustainable packaging is no longer a choice but a vital strand of operations that needs to be addressed.
UK-based dog food and packaging company Skinner’s CEO Tim Hansell tells Packaging Gateway why sustainability has become a vital factor to consider in the pet food packaging industry and how the national pet food packaging shortage gives evidence to this.
The packaging shortage situation
The pet food industry is worth over £2.9bn and is expected to grow 20% year on year. However, a year since the Covid-19 pandemic took hold, UK supermarkets have announced that the country is facing a national shortage of pouch food for dogs and cats, due to this unprecedented rise in pet ownership and the failure of supply chains to meet the new demand.
The shortage of pouches is predicted to continue throughout 2021, meaning that retailers will be forced to rethink their approach when it comes to packaging and supply chains. Covid-19 and Brexit have undoubtedly had an impact on the ability of certain brands to keep their cross-border supply chains flowing smoothly and maintaining products on shelves.
Demand for sustainability vs. preference for convenience
The challenge within the industry is to support consumer preference for both sustainability and ease, which has meant that pouches have continued to be a popular purchase choice. What supermarkets have failed to do on a large enough scale to meet demand, is offer products that are sustainable and will not face issues with production/imports whilst also offering high-quality food for dogs.
With the wide range of packaging products now available in the industry, one type of packaging doesn’t suit every need, which has caused issues for many manufacturers who have looked for a way to switch from their usual packaging. There’s also the issue surrounding the balance between using eco-friendly packaging that is also able to retain the full health and nutritional benefits of the product, and with all-natural ingredients sought by 41% of dog food buyers, there is no room for compromise.
The sector and its supporting retailers must act quickly to turn the tide on the impact of single-use plastics as billions of pouches every year are sent to landfill, with standard pouches having one of the lowest recycling rates of all packaging. This is around 50 times worse than the recycling rate of single coffee cups which continually draw media attention.
Sustainability has become the most important factor
The rise of the ethical and health-conscious consumer, and the wider spotlight on the sustainability agenda has forced the somewhat traditional pet industry to rethink every aspect of its offering, from packaging to manufacturing to ingredient sourcing.
Skinner’s: A case study
At Skinner’s, we identified the need to invest in a long-term solution and production technology that will help us navigate this tricky landscape and deliver the best products without compromising on sustainability credentials or nutritional values.
Skinner’s are this year celebrating 50 years of manufacturing high-quality food for working dogs and as part of our celebrations have undergone a total brand refresh with new logos, NPD and the introduction of our 100% recyclable packaging which we manufacture and produce at our two onsite factories in East Anglia.
The updated packaging on our Field & Trial range utilises Tetra Pak, made from over 70% paperboard. Tetra Pak is leading the idea that a circular economy, where every part of the process has a positive force on making a change, gives way to positive packaging for, in this case, the canine food market.
We have also introduced a new treats range which is packaged using Earthpouch plastic-free paper packing solutions, with an aqueous coating, it is 100% eco-friendly plastic-free paper packaging, proving that pouch packaging can be sustainable.
The capabilities to produce Tetra Pak on-site means that Skinner’s has not only reduced its carbon footprint, but we do not rely on imports and external manufacturers which has proved invaluable during the national packaging shortage crisis.
Sustainability isn’t easy – but it is worth it.
The journey to take manufacturing sustainably in-house is by no means simple, easy, or cheap as it requires heavy levels of investment and dedication to get it right, but the long-term impact is far worth it.
The current supply chain issues highlight the value of manufacturing close to home in the UK. The shortage also brings to light the need for the industry to continue to seek sustainable solutions.
The issue is now not only about protecting our planet’s future from plastic waste but has filtered down to the food our dogs eat and a lack of availability. It’s time for retailers to steer consumers towards more sustainable choices.
As more companies move towards biopolymers as an alternative to fossil-fuel-based plastic, some are considering hemp as a potential biomass source, but can this ‘wonder crop’ make an impact in the world of bioplastic? Heidi Vella investigates.
The humble hemp plant has long been known for its versatility: alongside bamboo, it is one of the quickest growing plants and is routinely refined into a variety of commercial items, including paper, textiles, and food products.It is, however, perhaps more closely associated with the drug cannabis, both of which are derived from the cannabis sativa plant. Although a different product altogether, it’s the US’s deregulation of this more infamous product that is driving a burgeoning new market – one using hemp to produce bioplastics for packaging.
The 2018 US Farm Bill changed federal policy, removing hemp from the Controlled Substances Act and allowing the consideration of hemp as an agricultural product: meaning farmers can now cultivate it industrially, the waste from which many say is an ideal bioplastic feedstock.
Why hemp?
In fact, one of the first companies to use hemp bioplastics in its products is a cannabis packaging designer and manufacturer. California-based Sana Packaging uses a fibre-reinforced biocomposite made from 30% micronised hemp herd and 70% polylactic acid (PLA), derived from plants such as corn and kenaf, to produce its premium packaging.
Sana co-founder & CSO, James Eichner, says that the company was inspired to use hemp as a feedstock for bioplastics as it has several agricultural advantages over corn, from which most bioplastics are derived.
“Two crops of hemp can be grown in the time it takes to grow one of corn, hemp requires around a third of the water corn does and because it is a canopy crop, it protects the soil from sunlight and erosion – unlike corn, which leaves the soil exposed. Hemp regenerates the soil, whereas corn depletes it,” explains Eichner.
Hemp is also known to absorb large quantities of CO2 from the atmosphere and can create a cellulose content – which is important for bioplastics – of 65%-75%. It is also flexible within crop cycles, due to its small harvesting period of only four months.
Sana initially started producing its packaging with pilot projects and then, when it could assure stability of supply, commercially at the beginning of 2019. Now the company is working with multiple suppliers.
Establishing a supply
However, Eichner says the supply chain for hemp feedstock is by no means comparable to other materials and it currently comes at a premium price.
CEO of US-based Hemp Plastics, Glen Kayll, says hemp bioplastics “can be less expensive than some PLA’s, depending on the base material, but more expensive than fossil fuel fuel-based resin.”
The major factor is that, as yet, there is no commercial availability of polymerized hemp plastic.
“It’s very early stages for hemp, but it is fundamentally a disruptive technology, driven by massive deregulation, which continues to play out around the world. The big swing in North America was the CBD market, which creates large amounts of industrial hemp waste that has made this opportunity more possible,” he explains.
California-based, Sana Packaging uses a fibre-reinforced biocomposite made from micronized hemp herd (30%) and PLA (70%), derived from plants such as corn and kenaf, to produce its premium packaging. Credit: Sana Packaging
The size of the global industrial hemp market is forecasted to grow at a CAGR of 13.7% between 2020 to 2025 and be worth $12.98bn by 2025. Difficulty refining end products from the crop and fluctuations of availability of raw materials, however, is restricting the market.
Like Eichner, Kayll believes hemp can address some of the environmental concerns around the growth of fossil fuel plastics, as well as the increase in industrial hemp waste.
“We realised that a large amount of hemp was going to be available and thought: wouldn’t it be great to find a way to reduce the amount of fossil fuel plastic and provide a product that is reasonably inexpensive and easy to implement and happens to look fantastic,” he explains.
Similarly to Sana, Hemp Plastics does not use 100% hemp-based plastic, but blends hemp plastics with various different thermoplastics, including fossil fuel and bioplastics, and custom blends.
Lack of infrastructure
While hemp is routinely used in other markets, Corey Kratcha, CEO of C2Renew, a biocomposite manufacturer that uses hemp as one of its inputs, says there is a lack of infrastructure for hemp bio-feeds.
“It’s a chicken and egg scenario with fibre processing in general. It usually starts with a pilot or small-scale investment in the equipment, but the output is so low that the economics to recoup the cost has to be much higher,” he explains.
“That can be prohibitive, there needs to be confirmation there will be revenue sources. We would use it readily if the supply was consistent.”
A challenge to investments in the industry could be that corn, the dominant feedstock for bioplastics, is heavily subsidised in the US. Farmers that produce commodity crops such as corn receive around 40% of their income from subsidies.
What we’re trying to do is recognise the need to move away from corn as a mono-crop in the US and as a feedstock for bioplastics.
“Corn has been subsidised for a very long time and hemp will not compete with it until either the hemp industry reaches a certain economy of scale through its own natural growth, or until hemp itself is subsidised, or until corn is no longer subsidised,” says Eichner.
“What we’re trying to do is recognise the need to move away from corn as a mono-crop in the US and as a feedstock for bioplastics.”
In Europe, where France is the predominant producer of hemp, the hemp packaging industry is as yet non-existent. However, the European Industrial Hemp Association is promoting it as a potential application and says the sector is becoming more organised and has “great opportunities ahead”.
The Association reports that there is currently an oversupply of hemp biomass in the EU, caused by the “hype” around CBD, which in turn has led to an ‘explosive growth in the number of cultivators, producers, and investors’.
It was recently reported that authorities in the Italian town of Roccasecca are exploring the potential for developing a hemp plastics supply chain while cleaning up local land, as the plant has remediation possibilities. A company called Eir Health also claims to be building the first factory in Europe to produce 100% biodegradable Hemp PLA.
Future potential
Despite hemp’s environmental credentials, some question the sustainability of bioplastics full-stop, noting that they are often non-recyclable and commercial compositing is still nascent.
Eichner agrees that the end of life argument is where the sustainability case for plant-based materials becomes harder to make.
However, Kayll says even if it is not biodegradable, reducing the amount of plastic used by 25% – the level of hemp used in Hemp Plastics’ products – is “meaningful”.
“If you are a company that’s running hundreds of thousands of tonnes of plastic every year, then that’s a very meaningful reduction, and it’s also a great way to sequester CO2,” he says.
While the hemp bioplastics sector is still fledgeling, Kayll believes in the future it will compete with other commodities due to its durability, versatility, and ease of growth.
“It’s a very valuable plant, there’s going to be many applications, it’s just going to take a while – industries take time to build, but the bioplastics and sustainable materials market is growing extremely quickly relative to your traditional incumbent markets,” says Kayll.
Indeed, by 2030, it is estimated that 40% of the plastics industry will be bioplastics. Furthermore, Kratcha says it only takes one huge company to start using hemp bioplastics to move the market.
“Hypothetically, if Walmart said it wants hemp composite in its clothes hangers it would very much move the needle,” he concludes.
