The REDYSIGN project, funded by the Circular Biobased Europe Joint Undertaking, is on track after 18 months, with progress going according to schedule. The initial phase has focused on Work Packages (WP) 2, 3, and 4, driving technical activities. These WPs cover transforming wood into high-value materials, developing smart packaging solutions (sensors, markers, and detection technology), and redesigning packaging parts (tray, pad, and film) to be fully biobased and recyclable. WPs 1, 6, and 7 are also making progress, while WP 5 is pending and will start soon.
In more detail, many technical activities have been performed over the first period of the project. For example, the high-consistency functionalization of lignocellulosic fibers has been deeply explored, by investigating four processes and several chemical and enzymatic routes. Successful treatments included phosphorylation, periodate oxidation, and laccase-mediated hydrophobization. Additionally, research on conical refiner and processing of functional TMP fibers into micro-nanofibers is showing promising results in fiber disassembly. The development of a wood sugar-based adhesive showed satisfactory adhesion properties, paving the way for its application in future tray-lidding film adhesion.
In the area of smart packaging, two distinct identification markers have been developed for use in REDYSIGN tray and absorbing pad products, an innovation that will enable improved sorting prior to packaging recycling operations. The project has also made progress in the detection of those traceability markers and contaminants, both in controlled lab and real-world, dynamic situations, combining machine vision with spectroscopy. Moreover, the development of anti-spoilage sensors for smart food packaging resulted in two innovative sensors, including a low-cost, printable device and a cold chain sensor with a memory option. The anti-spoilage sensor performed particularly well in testing, ensuring product quality and safety.
The project applied the Safe and Sustainable by Design (SSbD) concept to develop sustainable packaging solutions, identifying thirteen eco-design strategies that integrate sustainability and safety. Production trials of plastic-free trays commenced, resulting in some promising initial results. The identification marker was successfully incorporated to the wet-molded production process, making the trays detectable through Raman spectroscopy. In parallel, the dry-molding tray production process showed promising results, with the integration of a top coating made from an enzymatically-treated wood fraction successfully conferring hydrophobicity to the final product.
Research on the development of a fully biobased and sprayable barrier coating based on wood derivatives. Formulations based on lignin are being developed and some preparations have already proved to form a uniform hydrophobic layer on the cellulosic substrate surface, increasing its water resistance. Additionally, two independent technologies, dry-airlaids and ice-templating, are being explored for absorbing pads production, with promising results in the ice-templating approach.
Overall, the REDYSIGN project is making significant progress in developing innovative solutions for biobased packaging, addressing the need for sustainable and safe packaging alternatives. While challenges remain, the project is on track to achieve its goals of replacing non-circular plastic packaging with biobased alternatives.
