Development of innovative materials and processes for cellulose- based food packaging in a circular economy perspective

The thesis focuses on the development of innovative materials and sustainable processes for cellulose-based food packaging within the framework of a circular economy. The work, carried out in collaboration with Ecopack SPA, a leader in the design of paper forms for the food sector, aims to find eco-friendly alternatives to traditional plastics, reducing environmental impact and improving product sustainability. The thesis examines the evolution of food packaging and the transition towards the use of natural biopolymers such as cellulose, starch, pectin, chitin, and their derivatives. These materials offer more ecological solutions while maintaining the necessary properties for food protection. A central aspect of the research is the improvement of the barrier properties of cellulose-based materials, essential to ensure food safety and extend product shelf life. The functionalization of materials through surface treatments is analyzed to enhance resistance to gas and moisture, which are key factors in food preservation. A practical application of the research is the "Paper Pan Project", which aims to develop an innovative cellulose tray for the baking sector. The project includes various phases, from the selection of raw materials to the development of prototypes and the evaluation of technical and applicative performances. A key aspect of this project is the life cycle assessment (LCA) of the product, which allows evaluating the environmental impact of the tray, comparing it with traditional packaging solutions. The results highlight how cellulose trays can significantly reduce the use of natural resources, cut CO2 emissions, and facilitate material recycling. Another significant project explored in the thesis is the development of compostable sticks for Chupa Chups, offering a sustainable alternative to plastic sticks. The research process included experimentation and testing of innovative raw materials to evaluate performance and compatibility with food products. This development not only meets market demands but also demonstrates how sustainability can be integrated into everyday products. An additional innovative project presented is the creation of a line of products made from grass paper, a regenerative material that offers significant environmental benefits. Grass paper is a natural and biodegradable solution that reduces the use of tree-based cellulose, cutting down on water and energy consumption. The use of this material has led to the development of prototypes that meet market demands, in line with Ecopack's sustainability policies. All these projects emphasize the importance of research and development in creating sustainable packaging that meets the needs of both consumers and the global market. Innovative technologies and production processes are explored, which optimize raw material use and reduce waste. In conclusion, the thesis demonstrates how the adoption of bio-based materials and optimized production processes can lead to ecologically sustainable packaging solutions. These materials not only respect the environment but also offer excellent performance in terms of food protection and preservation. The work highlights how innovation in packaging is essential to tackle future environmental challenges, promoting the development of materials and technologies that reduce the environmental impact of packaging and improve the efficiency of the production chain