GREEN-LOOP | Sustainable manufacture systems towards novel bio-based materials

Rimini (IT), November 7, 2024 – GREEN-LOOP is a European project that enhances the manufacturing industry by refining bio-based materials and optimising production processes to offer solutions compliant with the European Packaging and Packaging Waste Regulation (PPWR). Among the key players in the project is the Italian company Mixcycling, which transforms agricultural by-products into bio-based materials ideal for various applications, focusing on sustainable packaging. Another project partner, Guala Closures in Breganze (Vicenza, Italy), is actively involved in designing new products and testing Mixcycling’s bioplastics for bottle closures for spirits that comply with European regulations (EC 1935/2004 and 10/2011), ensuring safety for contact with food, beverages, and pharmaceuticals.

As part of the GREEN-LOOP project, a new bio-based composite for injection moulding was developed and used to create initial prototypes of screw caps and oil dispensers. Additionally, an innovative microwave-assisted production process helps reduce energy consumption and improve material properties. New bio-based thermoplastics incorporating agricultural residues as fillers also show great potential for packaging. These advancements were presented by the project’s dissemination leader, NSBproject, in the paper “GREEN-LOOP: Sustainable Bio-based Materials and Circular Economy Solutions” during the Ecomondo 2024 conference in Rimini on November 5, 2024.

Solutions for Packaging Companies Compliant with the Packaging and Packaging Waste Regulation (PPWR)

The European Packaging and Packaging Waste Regulation, approved on April 24, 2024, aims to promote the circular economy by reducing the environmental impact of packaging and waste. The main goals include reducing waste volumes by optimising use of materials and designs that avoid excessive packaging; promoting reuse with long-term solutions; and increasing the share of recycled materials by improving collection systems and recycling processes. These principles are crucial for environmental sustainability and natural resource conservation, contributing to reduced pollution and carbon footprint. The PPWR introduces stricter requirements to reduce waste and enhance recyclability, creating new challenges and opportunities for companies. GREEN-LOOP demonstrates how bio-based materials can play a significant role in this transition, offering alternatives to traditional plastics within the PPWR framework.

With support from NSBproject, Mixcycling has developed materials for packaging and food closures. In collaboration with Guala Closures, bioplastic composites have been integrated into tamper-evident closures that match conventional plastics in terms of strength, hygiene, and flexibility. These closures, compliant with EC regulations, are safe for use with food, beverages, and medicines, reflecting GREEN-LOOP’s commitment to regulatory compliance and the development of sustainable materials. Technologies such as microwave-assisted injection moulding, which reduces energy consumption by up to 30%, pave the way for sustainable solutions that meet the standards of fossil-based plastics. Collaboration with industrial partners showcases the feasibility of integrating bio-based materials across various sectors, from food to cosmetic packaging. The bio-based materials proposed in the GREEN-LOOP project could potentially replace recycled plastic content, either due to a lack of recycled material or for quality reasons. As stated in Art. 8 of the PPWR, within three years from the regulation’s entry into force, the European Commission will review the technological development status and environmental performance of bio-based plastic packaging, taking into account the sustainability criteria outlined in Article 29 of Directive (EU) 2018/2001 of the European Parliament and the Council. Based on this review, the Commission may propose legislation to:

a) establish sustainability requirements for bio-based raw materials in plastic packaging;
b) set targets to increase the use of bio-based raw materials in plastic packaging;
c) introduce the possibility of meeting the regulation’s objectives using bio-based plastic instead of post-consumer recycled content.

Conclusion

GREEN-LOOP will continue to develop solutions for bio-based industries by improving material formulations, optimising production processes, and conducting rigorous tests to ensure scalability and market readiness. For the packaging sector, the project’s outcomes will offer tangible solutions compliant with the new European Packaging and Packaging Waste Regulation (PPWR).

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The GREEN-LOOP partners involved:

Guala Closures www.gualaclosures.com

Guala Closures offers high-quality, sustainable, and innovative closure solutions that ensure protection and convenience for end consumers while enhancing the value of brands. Guala Closures is a global leader in closures for the spirits, wine, beverages, oil, and condiments markets. With 35 production plants worldwide, the Group ensures proximity to its clients, offering tailored services and solutions. Guala Closures has over 5,000 employees.
Visit www.gualaclosures.com and follow the company page on LinkedIn.

MIXCYCLING www.mixcycling.com

Founded as a start-up in 2020 by brothers Gianni and Amerigo Tagliapietra, Mixcycling scaled up to become an industry player in 2023, earning international awards and recognition. It collaborates with major research centres and universities and participates in the GREEN-LOOP project funded by the European Commission, focusing on the research and development of high-performance, low-impact biopolymers (LCA – Life Cycle Assessment). Mixcycling’s technology is based on a patented process and proprietary technology that valorises organic waste and blends it with both bio-based and fossil-based materials, creating new raw materials for major industrial groups such as EssilorLuxottica, Stoelzle Glass Group, SCHID Spa, UniCredit StartLab, Adamo srl, Lavazza Group, Stilfibra srl, DeRoma Group, Selle Royal Group Spa, among others.

NSBproject www.nsbproject.com

NSBproject (NSB) supports large and medium-sized Italian enterprises in identifying, testing, and adopting innovative and enabling technologies, assisting with research, development, and technological innovation projects for products and processes. Leveraging a vast network of research entities and consortia across Europe and solid relationships with corporate partners and clients, NSB professionals contribute to the Italian and European innovation ecosystem with technological and financial scouting services. NSBproject is a partner in numerous Horizon Europe programme projects, serving as an Innovation Broker. Founded twenty years ago by professionals with expertise in technological innovation and extensive knowledge of national and European research and innovation funding mechanisms, CEO Fabrizio Riccomi, along with partners Andrea Jester and Rita Zanni, promotes and facilitates technology transfer, playing a key role in Italy’s economic system innovation, traditionally driven by foundations and universities. NSB is headquartered in Mantua, with offices in Veneto and Tuscany.