Forming and advanced characterization of monomaterial lignocellulosic packaging structure

Plastic packaging is a major source of environmental pollution, as it contributes to the 10 million tons of plastic waste that end up in the ocean every year. Cellulose-based materials, such as paperboard, could replace plastics in many applications including packaging. However, their limited formability properties prevent their widespread use. In Mon-Cell-Pack, VTT and LUT will collaborate to enhance the 3D converting and formability of cellulose-based materials by combining: 1) novel forming methods to create ultra-porous fibre networks, 2) biobased bonding solutions optimized with molecular simulations, 3) tailored pre-processing operation to maximize the material web’s elongation potential, and 4) final 3D forming operation guided by an advanced on-line characterization and finite element modelling of the material’s thermomechanical behaviour. The results will support the society in reducing plastic waste by replacing fossil-based materials with renewable, recyclable and biodegradable alternatives.

Besides the new novel technological concept, the project lays foundations for a completely new multi-scale simulation and characterisation approach to reveal the leading mechanisms that underly the 3D formability of fibre-based materials. This involves advanced molecular simulations to predict interface strength between biobinders and cellulose-fibre surfaces and a systematic experimental investigation of the subsequent effects in small-scale 3D samples with AFM methods and in-situ X-ray tomography. The applied real-time deformation analysis will enable the development of more specific finite element method (FEM) models to understand the forming behaviour of the fibre networks on a more accurate level than before.

Plastic waste from packaging is polluting our environment, as up to 10 million tons of plastic end up in the ocean every year. Cellulose-based materials, such as paperboards, have the potential to replace plastics in many applications including packaging. However, limited formability properties are hindering their use-potential. The solution for radical improvement in paperboard formability could be achieved by combining tailored fibre materials assisted with molecular and structural simulations and advanced 3D-forming characterization. This will lead to a better understanding of the material behavior under 3D-converting with thermomechanical stresses. The resulting leap in 3D formability of cellulose-based materials will help to reduce the amount of plastic waste by replacing fossil-based materials with renewable, recyclable and biodegradable raw-materials.