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FlexFunction2Sustain · Project

Sustainable Nano-Coated Packaging: Pilot-Ready Recycling and Biodegradable Film Production Lines

manufacturingPilotedTRL 7
flexfunction2sustain.eu

Imagine every plastic wrapper, food package, and paper surface you touch daily — most of them end up as waste because they're hard to recycle or break down. This project built a network of 9 connected pilot facilities across Europe where companies can test and produce smarter coatings for plastic and paper that are either fully recyclable or home-compostable. They upgraded real production lines to process 95% polyolefin films, recycle at 100 kg per hour with 30% better sorting, and make thin biodegradable films that still block oxygen. Think of it as a one-stop shop where a packaging company walks in with an idea and walks out with a tested, certified sustainable product.

By the numbers
100 kg/h
Recycling pilot facility throughput capacity
30%
Improved sorting accuracy in recycling
95%
Polyolefin-based film processing demonstrated
9
Connected lab-to-fab pilot facilities across Europe
20
Pre-commercial pilot cases completed
6
Industrial application scenarios demonstrated
€14.2M
EU investment in the project
25
Partners across 9 countries
The business problem

What needed solving

The packaging industry is caught between two urgent pressures: EU regulations demanding recyclable and biodegradable materials, and customer expectations for high-performance packaging that protects products. Most companies lack the specialized equipment and expertise to test nano-coatings, validate biodegradability claims, or redesign films for circularity without sacrificing barrier properties.

The solution

What was built

The project upgraded 9 connected pilot facilities into an Open Innovation Test Bed offering end-to-end services from TRL4 to TRL7. Concrete outputs include: a recycling pilot line processing 100 kg/h with 30% better sorting accuracy and PRE certification, a TÜV Austria-accredited biodegradability testing facility for home compostability and marine degradability, extrusion lines processing 95% polyolefin films, and compounding facilities producing 50-300 µm PLA composite films with oxygen barrier below 100 cm³/(m²d bar).

Audience

Who needs this

Flexible packaging converters needing to switch to recyclable or compostable filmsPlastic recyclers wanting to improve sorting accuracy and throughput for flexible wasteFMCG brands requiring certified compostable packaging for sustainability commitmentsAutomotive and electronics manufacturers using functional surface coatings on flexible substratesPaper coating companies exploring nano-functionalized barrier layers as plastic alternatives
Business applications

Who can put this to work

Flexible Packaging
mid-size
Target: Plastic film converters and flexible packaging manufacturers struggling with EU Single-Use Plastics Directive compliance

If you are a flexible packaging manufacturer dealing with pressure to make your products recyclable while maintaining barrier performance — this project built upgraded extrusion and film processing lines that demonstrate processing of 95% polyolefin-based films. Their facilities can help you reformulate products for circularity while keeping oxygen barrier properties, with PLA composite films achieving OTR below 100 cm³/(m²d bar).

Waste Management & Recycling
mid-size
Target: Plastic recyclers and sorting facility operators looking to improve throughput and accuracy

If you are a recycling operator dealing with low sorting accuracy and limited throughput for flexible plastic waste — this project upgraded the REMIX recycling pilot facility to handle 100 kg/h capacity with 30% improved sorting accuracy, and earned PRE certification. These proven process upgrades could be adapted to your sorting and recycling operations.

Consumer Goods & FMCG
enterprise
Target: Brand owners and consumer goods companies needing certified compostable or biodegradable packaging

If you are a consumer brand dealing with customer demand for compostable packaging but unsure if your materials actually break down at home — this project upgraded the BIODEGRADIX testing line and received TÜV Austria accreditation for verifying home compostability and marine degradability. You can use their services to test and certify your packaging claims before going to market.

Frequently asked

Quick answers

What does it cost to access these pilot facilities and services?

The project established a Single Entry Point (SEP) legal entity to provide services to companies across all EU countries. Specific pricing is not published in project data, but the OITB (Open Innovation Test Bed) model typically offers subsidized access for SMEs. Contact the coordinator for current service pricing.

Can these processes run at industrial scale?

The upgraded facilities already operate at meaningful pilot scale: the recycling line handles 100 kg/h with PRE certification, and the extrusion lines process 95% polyolefin-based films. The project was designed to bridge TRL4 to TRL7, meaning outputs are validated in industrially relevant environments but may need final scaling for full commercial production.

What about intellectual property and licensing?

The project involves 25 partners including 17 industry players and 6 SMEs. As an Innovation Action, IP from jointly developed processes is typically shared among consortium members. Companies accessing the OITB services would retain IP on their own products while licensing specific nano-functionalization processes. Contact the coordinator for specific licensing terms.

Does this help with EU packaging regulation compliance?

Yes. The project directly addresses the European Strategy for Plastics in a Circular Economy. The TÜV Austria accreditation for biodegradability testing and PRE certification for recycling processes provide recognized compliance pathways. The 6 industrial application scenarios were designed around real regulatory requirements.

How long does it take to go from concept to tested product?

The OITB supports companies at any point from TRL4 to TRL7 with integrated technological, business development, and verification services. The 20 pre-commercial pilot cases completed during the project demonstrate that the pathway from concept to pre-certified product is operational. Timeline depends on your starting point and application complexity.

Can I integrate these coatings into my existing production lines?

The project upgraded existing industrial equipment rather than building from scratch, which means the processes are designed for integration with standard extrusion, compounding, and film converting machinery. The 9 connected lab-to-fab facilities cover all major nano-surface processing techniques for flexible plastic and paper surfaces.

Is there ongoing support after the project ended?

The project established a permanent legal entity (Single Entry Point) with multiple regional front offices to continue offering services beyond the project period. The SEP was specifically designed to serve companies in all EU countries as an independent organization.

Consortium

Who built it

This is a heavily industry-driven consortium with 17 out of 25 partners (68%) coming from industry, including 6 SMEs — well above typical EU project ratios. Coordinated by Fraunhofer (Germany's largest applied research organization), the partnership spans 9 countries (AT, BE, CH, CZ, DE, EL, FR, IT, PT) with a €14.2M budget. The high industry ratio and presence of an established legal entity for ongoing services signal that this project was built for commercial exploitation, not just research publications. With only 1 university partner and 5 research organizations supporting 17 industrial players, the consortium is structured to move results into the market.

How to reach the team

Fraunhofer Gesellschaft (DE) — search for the FlexFunction2Sustain project lead at Fraunhofer ISC or Fraunhofer IVV, which handle surface and packaging research

Order a report on this consortium
Next steps

Talk to the team behind this work.

Want to access these pilot facilities or find out if your packaging challenge fits their service portfolio? SciTransfer can connect you directly with the right team at Fraunhofer and help navigate the OITB access process.

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