Global aspirations: PulPac’s cellulose technology can replace single-use plastics, says CEO

24 Oct 2019 --- PulPac, a patented technology that 3D-molds cellulose into strong and stable paper packs of any shape, is working with clients to set up production capabilities in Europe and the US as part of its quest for global commercialization. In this interview with PackagingInsights, Linus Larsson, PulPac CEO, explains the full potential of the technology to replace single-use plastic packaging at a lower price and on a global scale. “Our ambition is to disrupt the packaging industry and set a new and sustainable standard for packaging and single-use products,” Larsson says.

How does PulPac’s 3D molding technology work and what benefits does it bring?
Larsson: The foremost benefit of the PulPac technology is that it molds dry cellulose. That is the core of the innovation and what our patent comprises of. Dry-molding makes the process extremely fast and cost-effective compared to traditional methods of molding cellulose. Hence, the production cost for a PulPac product is very competitive compared to both single-use paper products and plastics. Other benefits are that we can easily make colored or patterned products and that the mold replication is very good, which enables, for example, high-quality embossing. The technology also gives us control of material thickness. We can produce very sturdy and thick products, but just as easily thin and material-effective products. There are cost advantages also in small runs and print on demand is a possibility in the future. Right now, our focus is on bigger volumes to get production capacity up and running.PulPac coffee pods.

What are the advantages of cellulose packaging over single-use plastics, particularly in terms of sustainability?
Larsson: In terms of sustainability, PulPac has all the advantages over single-use plastics. The material in a PulPac product is generic pulp, a renewable, recyclable and biodegradable material (a PulPac product can be recycled as paper, one of the most recycled materials globally). The main principle for PulPac is to design for purpose. The material is adapted to the application with a minimum of chemical additives. A PulPac product should last its use and then break down, regardless of where it ends up. As the raw material cellulose is cheaper than plastics, a PulPac product cost less to produce than a similar made of plastics. 

Besides sustainability, what other trends does PulPac tap into?
Larsson: The excellent moldability enables not only packaging but also other products of different shapes. A variety of possible shapes in connection with color and pattern gives a high degree of design freedom.

Are the barrier properties and durability of the material as strong as plastics?
Larsson: The hunt for the perfect barrier is of course what everybody is looking for. We have come pretty far with existing technologies, but we cannot beat plastics on durability and do not aim to. Plastic as a material in single-use products is overqualified! It’s used for a very short time but lasts for a thousand years before it breaks down. In that sense, it is rather an advantage of PulPac in single-use products and packaging that it does break down. A PulPac product can be cellulose only, which will dissolve in water within minutes. It can also be modified to hold moisture, liquids and even oil or to be strong and protect heavy products.PulPac coffee cup lid.

Which applications is PulPac most suited to?
Larsson: In short, high volume products. But PulPac can be used for most any single-use products and packaging, definitely foodservice/takeaway. We are currently working with clients in this segment and consider it a big potential market for PulPac. The foodservice sector has a lot of single-use plastic products that need to be replaced, both due to new legislation, consumer demand and environmental responsibility. We are also working in the Grocery segment as well as “non-food.” In the latter, our client Ekoligens is presently setting up big volume production of paperhangers using our technology.

Are there any food applications for which PulPac is not suitable?
Larsson: With new technology, there are of course low hanging fruits and there are others that require further development. At this point, we have not identified any food applications that would be unsuitable for PulPac. We focus on the most viable at this early stage. The harder the barrier, the more R&D it will take. PulPac is an R&D and IP house and we constantly identify, develop and improve barriers, depending on what is being requested.

How far along the commercialization path is PulPac?
PulPac trays.Larsson: Together with our clients, we are now setting up production capabilities in Europe and the US. As we are licensing the technology, there are no geographical limitations and PulPac aims to be totally global within a couple of years. The plan is that products will be launched throughout 2020.

What challenges are still left to be overcome?
Larsson: Scalability is our number one challenge. We need to make PulPac Machinery, which is a combination of available machinery adapted to our process, available on the global market. Lead times to get all equipment in place are long, from an entrepreneurial view, at least. The demand for our technology is massive. That puts high demands on our partners that supply the equipment and machinery.

What are PulPac’s aims and ambitions?
Larsson: We want to make change happen and make an impact at scale. Our ambition is to disrupt the packaging industry and set a new and sustainable standard for packaging and single-use products. We are at a crucial point in history when it comes to defining our future. We need to do a lot of things to become truly sustainable and circular. I believe Innovation such as PulPac will play an important role in that future.

By Joshua Poole