REDYSIGN and R3PACK: Collaborative EU Projects transforming packaging with cellulose fibre innovation

The development of sustainable, fibre-based packaging is a critical challenge in the drive to meet the European Green Deal’s objectives, with the ultimate goal of achieving climate neutrality by 2050. Horizon Europe, the EU’s flagship funding program for research and innovation, plays a pivotal role in facilitating the transition to a circular bioeconomy. Under its umbrella, initiatives such as the REDYSIGN and R3PACK projects are pioneering new, innovative solutions that push the boundaries of sustainability within the packaging industry with the collaboration of a multidisciplinary consortium of industrial partners and leading research institutes.

REDYSIGN focuses on the development of several resource-efficient processes dedicated to the production and circularization of a biobased, recyclable, and smart fibre-based packaging (FBP) alternative for fresh meat distribution as a substitute for current non-circular multi-plastic solutions.

R3PACK aims to address the challenge of transforming sustainable packaging through two complementary strategies: a “reuse” approach, focused on optimizing large-scale reuse schemes; and a “substitution” approach, centred on developing recyclable, fibre-based packaging alternatives. Both approaches cover a wide range of food categories, including fresh dairy products, fresh meat, sweet biscuits, doughs, ready-to-eat salads, cut fruits and even more.

A share foundation behind multiple approaches

Despite having distinct specific objectives, the REDYSIGN and R3PACK substitution strategy initiatives share a common outcome: the creation of a new fibre-based food packaging solution. Both projects focus on incorporating fibre in intermediate products and enhancing the recyclability of packaging materials.

A key area of convergence lies in the technical work on the functionalisation of cellulosic substrates to achieve high-barrier structures, aiming to reduce plastic usage. In REDYSIGN, the objective is to develop substitutes for each intermediate packaging product, including trays, barrier coatings, absorbent pads, cover films, and thermo-sealing adhesives, consisting almost exclusively (>98%) of wood-derived materials.

R3PACK also addresses on the functionalisation of moulded cellulose rigid trays to achieve high-barrier properties while keeping high fibre ratio (>90%) and high bio-based content ratio. The materials are developed to be recyclable and when possible, compostable.

Both initiatives align with the United Nations Sustainable Development Goals (SDGs) by promoting high bio-based ratios and fully recyclable packaging structures. They also follow the CEPI strategies, aiming to increase recycling rates to 90%, significantly surpassing the current 40% recycling rate of conventional plastic packaging.

Expected Impacts

The two EU projects aim to transform the packaging industry through legislative actions that foster the green transition, technological advancements, and increased consumer awareness of the climate crisis.

Both initiatives align with the EU’s 2050 strategy for a climate-neutral Europe. By focusing on redesigning packaging, they target the replacement of conventional plastic with bio-based and recyclable solutions. This shift is expected to reduce waste and emissions, increase circularity, and achieve substantial savings in energy and material consumption. R3PACK also adheres to this objective through its substitution approach, prioritizing sustainable materials that align with circular economy principles.

Throughout the projects, the development and dissemination of research findings will play a crucial role in advancing scientific knowledge and enhancing the scalability and transferability of sustainable packaging solutions. Making research documentation available to the scientific community is key to further improving concepts and applications.

The exchange of experiences and knowledge among leading research institutes and industrial partners is crucial for advancing sustainable packaging development. This collaborative approach not only accelerates innovation but, in addition, fosters a shared framework for implementing impactful, scalable solutions. As part of this effort, REDYSIGN recently participated in an event organized by R3PACK to introduce the project. This collaboration will continue, as R3PACK will be invited to participate in a REDYSIGN event to create a platform for mutual learning and strengthen synergies.