Three innovative biodegradable solutions for packaging
Biodegradability has become an increasingly important issue, largely due to growing concerns about the release of microplastics into seas, oceans, and marine ecosystems caused by conventional plastic packaging. However, not all materials labeled as “sustainable” or “bio-based” (partially or fully derived from renewable resources) are necessarily biodegradable. Although designed to reduce environmental impact, these materials can still fragment under specific conditions, particularly when exposed to heat or improperly disposed of.
Among the various players in this sector is the Italian startup SMUSH Materials, founded in 2024, which aims to transform local agricultural waste into industrial packaging designed to disappear, reducing environmental impact across the entire life cycle.
SMUSH packaging is part of a new generation of circular composite materials designed to replace single-use plastics, particularly foams and expanded materials (EPS, EPP, EPE), in industrial and design applications.
The materials are created by combining agricultural by-products with fungal mycelium, which are transformed through a proprietary fermentation process into 100% compostable structural components, certified TÜV Austria OK Industrial Compost.
The result is a lightweight yet mechanically strong material, naturally shock-absorbing, with performance comparable to EPS and up to 90% lower CO₂ emissions. The solutions are designed to be cost-competitive and aligned with future European regulations (PPWR and CE).
Another innovative solution is packaging made from untreated palm leaves, an agricultural by-product derived from the harvesting of Areca nuts. The production process begins with the collection of the leaves, which, instead of being burned -thereby releasing CO₂ into the atmosphere – are soaked in water and then hot-pressed into various stamps to create different types of packaging as an alternative to traditional plastic food containers.
The process does not involve the use of chemical agents and results in a durable material free from PFOA and PFAS, naturally resistant to liquids and fats for several hours thanks to the so-called “lotus effect” typical of palm leaves. This resistance can be further enhanced through the application of compostable coatings. The material is also compliant with REACH regulations and is certified carbon neutral, as well as compostable both in industrial facilities and in home and garden composting systems.
Another possible solution involves making polyolefin plastics – commonly used in packaging and food containers – biodegradable. To achieve this, a masterbatch has been developed consisting of 80% ECO⁺™, a patented additive containing oleophilic bacteria capable of consuming oils, and 20% dried coffee husks. The latter are sourced from local producers with the aim of supporting fair trade while also reducing the issue of agricultural waste burning.
The use of this masterbatch in the compounding process enables companies to produce biodegradable plastics at lower costs while maintaining high mechanical and functional performance. The additive has been tested by MTEC, which certified its biodegradability through landfill simulations, with no release of microplastics detected. In this way, rigid packaging and food-related applications could be reused while reducing water pollution and ensuring greater safety for both the environment and human health.
Among the most innovative low-impact solutions, a special mention goes to the Italian company Qwarzo, awarded in 2024 at Packaging Première for developing a mineral-based coating free from PFAS, capable of coating paper-based materials for single-use packaging without compromising recyclability.
At Packaging Première, Materially will be present from May 19th to 21st at Hall 3 – Stand C81.
In addition, Materially will be a partner in the Avant-Garde Award, dedicated to innovative materials and forward-thinking solutions.
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