A Finnish research consortium has demonstrated pilot-scale production of fully cellulose-based films and coatings that could help overcome one of the biggest challenges facing fibre-based packaging: achieving high barrier performance without relying on plastic layers.
Developed through the Films for Future (F3) project, the technology enables cellulose to be processed as a polymer rather than a fibre, creating transparent films and barrier coatings with performance characteristics comparable to conventional plastics while supporting recyclability or biodegradability at end of life.
Led by VTT Technical Research Centre of Finland and LUT University, the project brought together 34 industrial partners to develop alternatives to fossil-based packaging materials amid tightening regulatory requirements and growing pressure to reduce plastic use.
For the packaging sector, the development could be particularly relevant as brand owners and packaging manufacturers seek ways to improve the performance of fibre-based packaging while complying with emerging requirements around recyclability and material composition.
The work comes as implementation of the European Union's Packaging and Packaging Waste Regulation (PPWR) drives greater focus on recyclability, lifecycle performance and the reduction of unnecessary plastic in packaging systems. The researchers note that emerging thresholds for plastic content in fibre-based packaging are creating additional demand for alternative barrier technologies.
The project team says cellulose coatings achieved oxygen transmission rates (OTR) below 0.2 cc/m²/day and grease resistance rated at KIT 12, while maintaining compatibility with recyclable fibre-based packaging systems. The cellulose films demonstrated oxygen barrier performance below 1 cc/m²/day at 23°C and 50 per cent relative humidity.
According to the researchers, the materials can be processed using conventional package converting technologies, including thermoforming, potentially reducing barriers to industrial adoption.
“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,” said Ali Harlin, research professor at VTT and one of the project coordinators.
“At the same time, we are working with manufacturers to help them meet evolving regulatory requirements while maintaining product protection, shelf life, and process efficiency. Cellulose materials open new sustainable solutions for packaging.”
A key distinction of the F3 platform is that it addresses both functionality and end-of-life considerations. The films are inherently biodegradable, while the coatings have been engineered to remain compatible with fibre recycling systems and, where required, biodegradation pathways.
The project also demonstrated potential for cellulose films to function as standalone transparent packaging materials, opening opportunities beyond coated paper and board applications into flexible packaging formats traditionally dominated by plastics.
“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,” said Ville Leminen, professor of packaging technology at LUT University.
Completed in March 2026, the F3 project demonstrated the feasibility of producing cellulose-based films and coatings at pilot scale across multiple applications. The work involved collaboration between research organisations, industry partners and funding bodies, with a focus on advancing the technology from laboratory development towards scalable manufacturing.
Commercialisation is already under consideration. Carl-Erik Guttormsen, area director at Colombier Finland, said the project had enabled the development of fully plastic-free barrier coatings for paper and board packaging intended for demanding food applications.
Beyond barrier performance, researchers see potential for the cellulose platform to support next-generation active and intelligent packaging applications. Future developments could incorporate antimicrobial and antioxidant properties, as well as environmentally responsive functionality capable of reacting to humidity, gas composition or pH changes within a pack.
Project partners also highlighted the importance of adoption across the packaging value chain if cellulose-based materials are to transition from pilot-scale development to mainstream packaging applications.
The next stage of development will focus on improving barrier performance under humid conditions and integrating multiple functions into a single material system. Digitalisation and connected packaging technologies are also expected to play a role in future applications.
Initial commercial targets include dry food, bakery and fibre-based packaging applications requiring transparent barrier layers.
While further development is still required, particularly in maintaining barrier performance under high humidity, the project represents another step towards addressing one of the packaging industry's most persistent challenges: delivering the functionality of plastic barrier materials while retaining the recyclability and renewable credentials of fibre-based packaging.
Ed's note: Fibre-based packaging was impossible to ignore at interpack 2026, appearing in a growing number of formats and applications. Yet the industry's next challenge is not replacing plastic structurally, but replicating the barrier performance it provides. Research such as the F3 project highlights the type of innovation that could enable fibre-based packaging to make the next leap into more demanding applications.
