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Sustainable packaging company Mondi has partnered with advanced biomaterial engineers Traceless to develop a groundbreaking bio-circular coating solution based on agricultural byproducts.

The new coating is the first of its kind, offering a plastic-free alternative that meets the growing consumer demand for more sustainable packaging options.

Made from renewable plant-based materials, including residues from the agricultural industry, the coating eliminates the need for fossil raw materials.

According to a life-cycle assessment by Traceless, the new coating can achieve greenhouse gas emissions savings of up to 95% compared to virgin plastics, across the production and disposal phases.

The collaboration between Mondi and Traceless, which began in 2021, combines Mondi's expertise in paper coating and packaging solutions with Traceless' knowledge of developing material solutions based on natural polymers.

The coating granulates are currently produced in Traceless' pilot plant and applied to Mondi's kraft paper at the company's R&D centre for further testing. Future large-scale production is planned at a designated facility in Hamburg, Germany.

Extensive trials have confirmed that the kraft paper coated with Traceless' bio-based material can provide barrier properties against water, oxygen and fats, while also offering good printability – crucial features for a wide range of packaging applications, from ecommerce to frozen and fatty foods.

"We are always looking at what the next steps are in creating truly circular packaging, following our customers' demands as well as our own innovative spirit," said Marko Schuster, COO of Mondi's Functional Paper and Films division. "This is a fantastic example of how we can combine our R&D forces to be one step ahead in the sustainable packaging game, contributing to a circular economy."

Anne Lamp, CEO and co-founder of Traceless, added: "Our mission is to make pollution and waste history by using materials that impact positively. The goal is to create a truly fit-for-purpose product, that works for as wide a range of applications and industries as possible."

The companies aim to further optimise the properties of the bio-based coating to make it suitable for a variety of packaging applications across different end markets while ensuring recyclability within existing European recycling streams.

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