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Researchers from VTT Technical Research Centre of Finland and LUT University have successfully advanced fully cellulose-based films and coatings through the Films for Future (F3) project, creating materials designed to replace conventional plastic packaging while addressing increasingly stringent regulatory demands.

The development comes as the industry faces mounting pressures to reduce the use of plastics and comply with new legislation, including the EU’s Packaging and Packaging Waste Regulation, which introduces stricter requirements around recyclability.

The F3 platform enables cellulose to be processed as a polymer rather than a fibre, resulting in transparent films that offer mechanical strength and barrier properties comparable to traditional plastics. Unlike other bio-based alternatives, the materials are designed to deliver both functionality and improved end-of-life outcomes.

Ali Harlin, research professor at VTT and one of the project’s lead coordinators, said: “Plastic films are one of the most widely used packaging formats, yet they are among the most difficult to recycle and a major source of persistent environmental pollution.”

The technology has been engineered with industrial adoption in mind. Researchers say the films and coatings can be integrated into existing converting processes and are compatible with current recycling systems or biodegradation pathways, depending on the application.

Ville Leminen, professor of packaging technology at LUT University and leader of LUT’s sub-project within F3, said: “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.”

For food and beverage manufacturers, the most immediate opportunities are expected in dry food applications, bakery packaging and fibre-based formats requiring transparent barrier layers.

Pilot scale results indicate that the cellulose films provide oxygen barrier performance with oxygen transmission rates below 1 cc/m²/day at 23°C and 50% relative humidity – performance levels comparable to conventional packaging materials.

Carl-Erik Guttormsen, area director at Colombier Finland, said: "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. Utilising our off-line coating line, we are now able to commercialise these solutions on paper and board for demanding food packaging applications."

The project also highlighted the importance of scalability and compatibility with existing infrastructure

Riku Talja, development manager at Metsä Board, said: “Solutions that align with current converting technologies and recycling infrastructure are far more likely to transition from pilot-stage innovation to industrial use."

Researchers believe the platform's potential extends beyond traditional packaging applications.

Future development efforts will focus on enhancing barrier performance under humid conditions and incorporating additional functionalities such as antimicrobial and antioxidant properties. The technology could also support the development of active and intelligent packaging systems capable of responding to environmental conditions, including humidity, gas composition and pH.

Mats Berg, senior principal scientist, discovery & innovation at Kemira, said: "Value chain adoption of these platforms is essential for the ongoing transition towards fully renewable and recyclable technologies. We see chemistry as the key enabler for this transition."

Completed in March 2026, the F3 project involved collaboration between VTT, LUT University and 34 industrial partners, with funding provided through the European Regional Development Fund (ERDF). The initiative focused on advancing cellulose-based materials from laboratory development toward scalable manufacturing solutions.

Vinay Kumar, senior scientist at VTT, said: "The key challenge has not been whether alternative materials exist, but how to process them in a way that meets industrial requirements. What has now been demonstrated is a future-ready material platform that offers an alternative to plastics, combining sustainability with the capability to integrate into existing manufacturing and recycling systems."

The Films for Future (F3) research project brought together VTT Technical Research Centre of Finland, LUT University and 34 industrial partners to develop environmentally friendly packaging solutions. The programme was funded by the European Regional Development Fund (ERDF) and focused on accelerating the commercial readiness of renewable, high-performance packaging materials.