Cellugy has developed EcoFLEXY, a biopolymer from fruit waste. EcoFLEXY ready-to-use packaging films can be produced at a comparable cost to fossil plastics, due to an innovative “white biotechnology” production process: aerobic fermentation produces a unique, 100% pure, nanomaterial combining the positive attributes of cellulose with qualities such as extraordinary mechanical strength. Most food packaging solutions made from fossil-based plastics are produced and consumed in an unsustainable manner. They emit greenhouse gases during production and degradation; the majority of food packaging is intended for single-use, while it takes hundreds of years for the material to degrade; large volumes of food plastic packaging ends up as litter, resulting in high waste management costs and the pollution of our ecosystem; and plastics are entering the food chain with potential harmful effects on human health. There is an urgent need for bio-based alternatives. Given the emphasis that policy makers and consumers are placing on environmental issues, bio- based food packaging is likely to grow by 28.3% between 2018 and 2024. Related to the UN Sustainable Development Goals 2 and 12, Cellugy is taking action and facilitating the transition towards more sustainable food packaging solutions. EcoFLEXY is: produced from food waste (second-generation feedstocks); simple and cheap to produce through a near carbon-neutral production process; avoids microplastics pollution in the ocean; is home compostable and is recyclable in the existing system. By 2026, Cellugy aims to be a leading player in the €0.9bn global market for flexible packaging for the food industry with a market share of 2.4%. This feasibility study will permit Cellugy to confirm customer requirements for sustainable packaging, explore different food applications and specify target markets, validate the production process and identify the resources required to support growth.

Plastic pollution is a dramatic problem of our times. A large percentage of plastic production is destined to packaging, which is designed for single use but at the same time can stay in the environment for thousands of years. Efforts to replace conventional, oil-based plastics with more environmentally friendly materials have so far failed due to their reliance on food crops and end-of-life challenges. Cellugy has designed EcoFLEXY, a biomaterial able to replace plastics in several packaging applications, which is completely harmless to the environment. EcoFLEXY is produced by bacteria and yeast starting from sugar or agro-industrial waste, in low-energy conditions. Being made of nanocellulose, EcoFLEXY can be either recycled in the paperboard stream or home composted, whereas if leaking into the environment it safely biodegrades in a short time, leaving no toxic residues behind. EcoFLEXY production emit 94% less CO2 emissions compared to conventional plastics and at the same time enables a circular economy by making use of second-generation feedstocks. Cellugy will first sell EcoFLEXY to packaging companies and chemical companies serving them. It will start marketing Cellugy in Northern Europe where consumer and customer demand for sustainable products is highest. EcoFLEXY will be sold at a price competitive to that of bioplastics, leveraging on important collaborations within the chemical and packaging industry. To reach market launch, Cellugy will expand its production from the laboratory to a full industrial volume scale in a stepwise manner, with considerable interest from prospective investors in the biotech sector to follow product development. Cellugy’s team is well-rounded and led by award-winning entrepreneur Dr Isabel Alvarez Martos.

Human pathogens can persist on textiles and high-traffic surfaces for hours, days or even longer when protected in biofilms, increasing risk of infection spreading. Conventional cleaning has no lasting effect as contamination can re-occur almost immediately. Available antimicrobial coatings are based mainly on the release of silver ions and other biocides that present risks for resistance development and environmental damage. Inorganic nanoparticles are also a concern for human health. Nanocellulose is a versatile nanomaterial obtained from wood pulp or biotechnological methods, which has excellent physical properties for coatings, enabling controllable and standardised application of antimicrobial functionalities. In Triple-A-COAT the 3 forms of nanocellulose will be augmented for antimicrobial/antiviral activity through grafting/adsorption of novel, resistance-proof compounds with excellent activities against bacteria, fungi and/or viruses, and nanopatterning to create bio-inspired antimicrobial surfaces. Spray coating and thin film applications will be developed, optimising adherence to plastic, metal, textiles and glass. The most effective coatings will be evaluated for antimicrobial/antiviral activity, durability and non-toxicity using ISO standard tests, and in a simulation of a bus environment over 6 months to reach TRL6. A life cycle assessment of the platform will also be completed. The project consortium involves companies, academic and SME partners with leading expertise in novel antimicrobial and antiviral technology, nanocellulose production and functionalisation, coatings development and characterisation, as well as a bus manufacturer and an external User Committee. Within 5-10 years after the end of the project, the results will be commercialized for impact in the transportation and healthcare sectors, contributing to the better control of infectious disease, and boosting the competitiveness and research leadership of EU industry including SMEs.