Cellulose films move closer to replacing plastic in packaging

A new bio-based material platform developed in Finland is bringing fully cellulose-based films and coatings closer to commercial reality, offering the packaging industry a potential alternative to fossil-based plastics without sacrificing performance.

Developed through the F3 – Films for Future project by VTT Technical Research Center of Finland and LUT University, the technology enables cellulose to be processed as a polymer rather than a fiber. The result is transparent films and barrier coatings with mechanical and functional properties comparable to conventional plastics, while supporting recyclability in fiber streams or biodegradability depending on the application.

The development comes as regulatory pressure intensifies, particularly under the EU’s Packaging and Packaging Waste Regulation (PPWR), which is pushing converters and brand owners to reduce plastic content and improve recyclability. The F3 platform directly addresses those requirements by enabling high-performance materials that can integrate into existing converting processes.

“Plastic films are one of the most widely used packaging formats, yet they are among the most difficult to recycle,” says Ali Harlin, research professor at VTT. “At the same time, manufacturers need to maintain product protection, shelf life, and process efficiency. Cellulose materials open new sustainable solutions for packaging.”

The materials have already been demonstrated at pilot scale across multiple applications. Films offer oxygen barrier performance (OTR below 1 cc/m²/day), while coatings achieve even higher barrier levels (OTR below 0.2 cc/m²/day) along with grease resistance (KIT 12), making them suitable for food and fiber-based packaging formats.

Equally important for converters, the platform has shown compatibility with conventional processing methods, including thermoforming, supporting integration into existing production environments without major equipment changes.

“The key challenge has not been whether alternative materials exist, but how to process them in a way that meets industrial requirements,” says Vinay Kumar, senior scientist at VTT. “What has now been demonstrated is a material platform that can integrate into existing manufacturing and recycling systems.”

Beyond replacing plastic films, the technology also opens the door to more advanced packaging applications, including barrier coatings with added functionality such as antimicrobial or responsive properties. Initial commercialization efforts are expected to focus on dry food, bakery, and fiber-based packaging applications requiring transparent barrier layers.

“The cellulose films and coatings have already been demonstrated to have the properties to be processed in various package converting processes, which highlights their future potential,” says Ville Leminen, professor of Packaging Technology at LUT University and the leader of LUT’s sub-project.

“Finding the right balance between functionality and sustainability is critical for the future of packaging. Through the F3 project, we have bridged this gap by developing fully plastic-free barrier coatings that deliver high performance without ecological compromise. Utilizing our off-line coating line, we are now able to commercialize these solutions on paper and board for demanding food packaging applications,” adds Carl-Erik Guttormsen, area director at Colombier Finland.

With pilot-scale feasibility now established, further development will focus on scaling production and improving barrier performance under more demanding conditions, including high humidity.

The next phase will focus on scaling the technology toward commercial applications, with initial use cases in dry food packaging, bakery products, and fibre-based packaging requiring transparent barrier layers. The films provide oxygen barrier performance (Oxygen transmission rate, OTR below 1 cc/m2/day) comparable to conventional plastics at 23°C and 50% RH, while the coatings enable oxygen (OTR below 0.2 cc/m2/day) and grease barrier (KIT 12) functionality in recyclable fiber-based packaging systems.

In addition, future developments will target integration of multiple functionalities within a single material system. Digitalization, including sensor-enabled or connected packaging, is also expected to play a role in future applications.