The demand for sustainable packaging is continuously growing. Developing high-performance bio-based coatings for cellulosic materials has become increasingly important. During her research visit to Grenoble INP-Pagora, Sahar Babaeipour focused on developing grease and moisture barrier coatings based on lignin nanoparticles for 2D and 3D cellulosic packaging.
Cellulosic packaging is an excellent renewable and biodegradable alternative to conventional plastic-based packaging but its natural hydrophilicity is challenging when it comes to packaging greasy and moist foods. Without an effective barrier, fiber-based trays can absorb water and oils, compromising their mechanical integrity and leading to leakage or structural failure. To address this, the industry has long relied on fluorinated chemicals (PFAS) to create water- and grease-resistant surfaces. However, increasing environmental and health concerns have led to regulatory actions phasing out PFAS in food packaging. There is an urgent need for more sustainable alternatives that provide similar functionality while being safe and recyclable.
Lignin is a promising alternative for developing bio-based barriers due to its natural hydrophobicity and antioxidant properties. Sahar's research focuses on utilizing lignin nanoparticles (LNPs) to enhance the barrier properties of cellulosic packaging. By incorporating these nanoparticles into coatings, her research aims to improve resistance to water, grease, and water vapor, extending the applicability of fiber-based materials for food packaging.
In Grenoble, professor Julien Bras' expertise in the packaging field, along with Grenoble INP-Pagora’s specialization in paper and bio-based materials, provided an excellent research environment for testing these coatings, allowing to evaluate how these lignin-based coatings perform under industrially relevant conditions.
Beyond improving barrier performance, another critical aspect of this research is ensuring that these coatings do not compromise the recyclability of fiber-based trays.
By developing fully bio-based and water-dispersible coatings, Sahar Babaeipour aims to create a functional yet recyclable packaging solution. This aligns with the increasing regulatory emphasis on circular economy principles, where packaging materials must be easily recyclable or compostable after use. This approach ensures that the coated trays maintain their recyclability, supporting a more sustainable packaging industry.
The research visit to Grenoble INP-Pagora was invaluable in advancing scalable and industrially relevant lignin-based coatings. By integrating bio-based materials, scalable coating technologies, and recyclability considerations, the research team moved closer to developing the next generation of sustainable food packaging. This experience underscored the importance of bridging fundamental research with industrial feasibility to create materials that are not only technically viable but also commercially and environmentally sustainable. The visit led to joint publications and a conference presentation, further contributing to the field.
This work has been done with the support of Jane and Aatos Erkko foundation.
The doctoral research conducted by Sahar Babaeipour, a doctoral researcher at Aalto University’s Bioinnovation Center, aims at a more sustainable packaging industry.
To achieve human wellbeing in planetary boundaries, we need new sustainable solutions to wisely use our natural resources. The Bioinnovation Center especially focuses on innovations in sustainable bio-based materials, with special focus on textiles and packaging.
