Develop and scale-up (TRL4-TRL6) the manufacture of a biobased, recyclable and biodegradable coating for paperboard packaging as a replacement for current petrochemical-based or fluorochemical materials

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COVID-19 has only accelerated the rising trend of takeaways and food delivery services, with the UK foodservice market reaching over £60 billion in 2021 with predicted CAGR \>14% from 2021-2026\[2\]. However, the convenience of takeaway and food delivery services come at a significant sustainability cost: an increase in single-use packaging, predominantly single-use paperboard trays and boxes. Although made from a sustainable material, paperboard, these trays and boxes usually contain a thin coating made from petrochemical-based polymers or fluorochemicals. These coating provide a functional barrier to grease and water which help maintain the structural integrity and prevent leakage or contamination of the package during transportation and use. Unfortunately, separating the paperboard from these coating can adversely affect recyclability.For single-use plastics with readily available alternatives (e.g., disposable polystyrene cups/lids, cutlery, plates, straws), plastics bans have already been introduced in the UK and the EU. Despite strong public support for more stringent ban on single-use plastic packaging (described by campaign group A Plastic Planet as "useful for moments, polluting for centuries"), the lack of an alternative for food contact barrier coatings currently hinders the introduction of a ban.Inspired by nature, Xampla has developed the next-generation bio-based and biodegradable materials produced from plant proteins. By harnessing the natural ability of plant proteins to self-assemble, we have created a new range of materials with remarkable functional properties. Xampla's plant protein-based materials can be used to produce functional materials with highly controlled properties, including coatings for packaging applications. Our coatings can be applied to a variety of substrates and tailored for use with a range of goods (e.g. food and cosmetic packaging) to deliver a sustainable packaging solution. Xampla's plant-protein based coatings offer excellent grease and oxygen barrier properties, without negatively impacting user experience.With Innovate UK support, we will develop and scale-up the manufacture of a bio-based and biodegradable packaging coating as a replacement for current petrochemical-based or fluorochemical materials. We will scale out our approach in the UK with a leading consumer packaging manufacturer and through consumer trials with a leading takeaway food provider. We will also work with established cosmetics packaging manufacturers to develop a similar solution in this sector.The outputs from this project will support the UK's ambition to become a world leader in sustainable packaging, significantly impacting 2025 UK Plastics Pact target 1, addressing widely known problems related to plastic packaging for consumer products.