Public Funding for Pulpex Limited

Pulpex is committed to achieving net-zero emissions, and this project aims to use enzyme treatments to improve the stiffness, strength and detail of paper fibres for moulded recyclable materials. The goal is to produce sustainable paper components by enzyme-based processing that will replace plastic parts, like the threaded piece between a bottle and its lid. Building on a previous project that developed paper lids, this new project focuses on creating a strong, sustainable threaded fixing mechanism for paper bottles using enzyme-enhanced cellulose. This effort combines the expertise of Bangor University in fibre and enzymes, Scitech Adhesives in formulations, and Pulpex in fibre moulding, making it a collaborative UK scientific endeavour. The main objective is to test whether enzymes can be integrated into manufacturing to strengthen these paper fitments. Currently, plastic fitments are precise, light, and stiff but not easily recyclable. The project aims to improve paper fitments with enzyme additives to match the precision and stiffness of plastic ones, supporting Pulpex's sustainability goals. Unlike previous projects that used compression moulding and sustainable materials for lids, this project will enhance the mechanical properties of paper-based threaded closures with enzymes. By boosting cellulose cross-linking, the strength and durability of paper solutions will improve, moving closer to fully biogases paper bottles. The focus is on proving that enzymes can enhance cellulose manufacturing, making it a sustainable innovative, viable alternative to plastic. This project will help bring enzyme-treated paper fitments to market and scale up their production.

Pulpex, collaborating with ASTUTE, pioneers sustainable packaging solutions, converting cellulose fibre into easily recyclable bottles for FMCG brands. We aim to analyse barrier coating layers for defects in the process in real-time at scale. Our project focuses on enhancing the manufacturing process of paper bottles pioneered by Pulpex, a leader in sustainable packaging solutions. By collaborating with ASTUTE, we aim to develop automated, non-destructive techniques to analyse barrier coating layers for defects and pinholes at scale. With over 1.3 trillion glass and plastic bottles produced annually, our innovative approach addresses the growing demand for eco-friendly packaging alternatives. The project targets real-time analysis in high-volume manufacturing environments, which is crucial for ensuring product integrity, quality control and reducing packaging failures. Leveraging Pulpex's patented technology and ASTUTE's unique expertise, we aim to revolutionise the fast moving consumer goods (FMCG) packaging industry by providing scalable solutions for sustainable packaging solutions.

The '_Pulpex UK BioScience Initiative_' will help Pulpex Ltd fully achieve its medium-term ambition by replacing its existing petrochemical-based barrier coatings with truly sustainable coatings as barriers to water and foods. The barrier coatings are applied on the interior of the Pulpex sustainable bottle. Sustainable materials are the future of food packaging; consumers, general public and corporates are demanding this product now. Pulpex has already demonstrated the manufacture of a paper bottle that will enable brands to switch from glass or plastic to a sustainable alternative that is readily recycled. Pulpex has developed an advanced manufacturing process that converts cellulose fibre into a bottle that can be easily recycled through the existing and well-established paper collection schemes that are available throughout the UK. Pulpex are partnering with two UK bio-manufacturing firms. CuanTec is a world leading firm based in the European Centre for Marine Biotechnology in Oban who produce chitosan from waste material from shellfish using a proprietary fermentation process. CelluComp is an established company based in Fife with deep expertise in the extraction of micro-fibrillated cellulose (MFC) from waste root vegetables using bioprocessing techniques. These are world-class companies based here the UK and seeking expanding markets for their products. This ambitious collaborative project draws on scientific expertise from across the UK to accelerate the adoption of bioprocessing-derived barrier coatings for Pulpex's breakthrough fibre bottles and other high barrier packaging applications. The incredible calibre of our partners is testament to the high standards we aspire to. The project offers deep industry and academic collaboration across the entire supply chain -- converting non-food waste (e.g. shells from crustaceans and discards from root vegetables) into high value high barrier packaging that is market ready and validated. We see properly bioprocessing as essential to the development of the next generation of sustainable products. The project aim is to deliver and accelerate commercial high barrier products -- derived from the bioprocessing / fermentation of chitosan and MFC from vegetal waste streams -- that can be effectively applied to Pulpex fibre bottles at scale and certified as suitable for liquid food use.

This project will help Pulpex Ltd fully achieve its net zero ambition by replacing its existing plastic lids with a biobased closure for its innovative paper-based bottles. Pulpex has demonstrated that it is possible to manufacture a biobased bottle that will enable brands to switch from glass or plastic to a paper-based alternative that is readily recycled. To achieve this aim, Pulpex has developed an advanced manufacturing process that converts a biobased feedstock (cellulose fibre) into a bottle that can be easily recycled through the existing and well-established paper collection schemes that are available throughout the UK. Currently Pulpex lids are made from plastic and the ambition is to develop a new lid that is 100% biobased. This lid will have superior functionality and will be easily recycled. The project aim is therefore to assess the feasibility of using a compression moulding process to produce a biobased lid manufactured from a combination of different biobased feedstocks. These lids will be fit for purpose and certified as recyclable in the paper waste stream.

Pulpex Ltd is a proven, patented and scalable packaging technology company ready to be deployed globally and promising to herald in an exciting and greener future. As a unique, first-of-its-kind pulp packaging solution that uses technological innovation to deliver much-needed and highly anticipated eco-packaging category change, Pulpex offers a disruptive, renewable pulp bottle technology created by industry for industries that use bottles and other packaging worldwide. Pulpex fibre bottles are formed by pressurising pulp in moulds using highly advanced technology. The fibre containers are then cured in microwave ovens before being sprayed internally with specialised coatings designed to be compatible with the products they are holding. Made from sustainably sourced wood pulp that is PEFC-accredited and FSC-certified, Pulpex holds both PEFC and FSC Chain of Custody certifications. Pulpex fibre bottles are not plastic bottles with a fibre shell, nor are they plastic infused with fibre. Our bottles are kerbside paper-stream recyclable and degrade readily in the natural environment. Pulpex technology was invented in and is currently headquartered in the UK. To date, millions have been invested in the technology and we employ over 50 people at our R&D facility in Sawston, Cambridgeshire. This feasibility project in conjunction with the University of Nottingham will investigate using bio-based formulation technology for waterborne coatings for paper bottles based on natural waxes and forest-derived products. The experimental work will be housed at Food Sciences, within the School of Biosciences, Sutton Bonington Campus. This feasibility project and the Pulpex product itself will help establish the UK as the thought leader in reduced plastic and plastic-free packaging technology. Pulpex has developed corporate partnerships with leading global CPG companies focused on reducing both their reliance on plastic and their carbon footprint, proving both interest and demand for fibre bottles made using Pulpex technology. Together, our goal is to harness the ecological credentials of pulp and bio-based materials to champion a revolutionary approach to packaging -- a present day 'hot topic' on almost every corporate CSR and sustainability agenda.