Barrier Breakthroughs: The Future of Molded Fiber Products and Environmental Sustainability

Innovations in barrier technologies and biodegradable polymers underscore a commitment to creating products that do not harm the environment. © Heorshe – stock.adobe.com

Contributed by the International Molded Fiber Association

The increased use of molded fiber over petroleum-based products is a significant step forward in environmental sustainability and stewardship. Molded fiber products are gaining prominence due to their biodegradable and compostable nature; however, certain molded fiber products require lamination to maintain quality and functionality.

To confront this challenge, many companies and research institutions are working on innovative solutions to reduce or eliminate plastic use in molded fiber products. In this article, we aim to provide an in-depth look at why lamination is necessary, what companies across the globe are doing to reduce plastic use, and the exciting advancements making molded fiber products more sustainable.

The Necessity of Lamination in Molded Fiber Products

Lamination is crucial for certain molded fiber products to ensure durability, water resistance, and to maintain food safety standards. Omnipac Group, a prominent player in the food service packaging and single-use medical hygiene products market, highlights the need for lamination to preserve product integrity. For instance, food service packaging must be grease-resistant and sturdy enough to handle different food types without compromising hygiene standards. Similarly, single-use medical products require a barrier to prevent contamination and ensure sterility.

Efforts to Reduce Plastic in Lamination

Molded fiber producers across the globe are actively working to maximize the use of sustainable materials in lamination while upholding product quality. Genera, for example, focuses on compostable food service packaging, aiming to create products that break down naturally without leaving harmful residues. Their advancements in compostability help reduce the environmental impact of single-use items.

Imerys Minerals offers an alternative approach with their innovative barrier coatings. These coatings provide the necessary protection and performance typically achieved through polyethylene (PE) lamination but without relying on traditional plastics. This advancement is crucial in improving the recyclability and compostability of molded fiber products.

Cutting-Edge Innovations in Sustainable Barriers

If our present-day objective is to reduce the number of non-renewable resources used in molded fiber product lamination, tomorrow’s goal is to eliminate these materials entirely with novel sustainable barriers. Research and development in sustainable barriers are at the forefront of making molded fiber products entirely recyclable and compostable.

Innofibre is a research-based institution dedicated to developing cellulosic products. Their analytical labs and pilot testing areas allow for the exploration of new technologies that can replace traditional plastic barriers. This research is vital for creating molded fiber products that are both high-performing and environmentally friendly.

Borregaard is another key player in this space, focusing on Microfibrillated Cellulose (MFC). MFC is a bio-based and multifunctional product derived from cellulose, providing enhanced strength and barrier properties to fiber-based products. This innovation is pivotal in making molded fiber products stronger and more versatile while ensuring they remain compostable. By using MFC, Borregaard aims to eliminate plastic barriers entirely, paving the way for fully sustainable molded fiber products.

NatureStar Global is making significant strides with their 100% biodegradable and compostable polymer, NatureResin. This innovative material is derived from plants and performs similarly to traditional plastic but fully composts in soil within a few months. This rapid decomposition contrasts sharply with the centuries it can take for conventional plastics to break down. By incorporating NatureResin into their food packaging, NatureStar Global demonstrates a viable path forward for reducing plastic pollution and promoting environmental sustainability.

Innovations in barrier technologies and biodegradable polymers underscore a commitment to creating products that do not harm the environment. By reducing or eliminating the need for plastic lamination, these advancements ensure that molded fiber products can break down naturally, returning valuable nutrients to the soil and reducing the burden on landfills.

The Future of Packaging

Through the combined efforts of companies across many areas of expertise, significant progress is being made in reducing or eliminating plastic in molded fiber products. These advancements not only enhance the performance and functionality of molded fiber products but also contribute to a more sustainable environment. As research and innovation continue to drive the industry forward, molded fiber products are poised to become a cornerstone of sustainable packaging solutions, helping to protect our planet for future generations.

About the Contributor

The International Molded Fiber Association (IMFA) is the only global not-for-profit trade association representing the interests of manufacturers of molded fiber products, industry suppliers and service providers. As the principal worldwide source of molded fiber information since 1997, we foster, educate, develop and lead the industry in pursuit of technological, manufacturing and sustainability intelligence. To learn more or join, visit https://www.imfa.org/