Pioneering the Future of Sustainable Packaging: SustaPack’s Breakthrough Innovation
A new, game-changing research initiative, SustaPack, is setting out to redefine the future of sustainable packaging. With a £1 million grant from the Engineering and Physical Sciences Research Council (EPSRC), this multimillion-pound project is a collaboration between Pulpex Ltd and the University of Surrey to tackle one of the biggest manufacturing challenges in sustainable packaging: creating next-generation, paper-based liquid containers that are both high-performing and eco-friendly.
Pushing the Boundaries of Sustainable Packaging
Pulpex, known for its patented wood-fiber bottle technology, has already made impressive strides in providing a recyclable alternative to plastic. Their innovative bottles, made entirely from natural materials, can be processed through existing paper waste streams—offering a genuine, sustainable solution to plastic pollution. However, scaling this breakthrough to industrial levels requires new approaches to manufacturing, coating technologies, and quality control.
That’s where SustaPack comes in.
“We’re excited to strengthen our collaboration with the University of Surrey to advance our technologies and processes,” said Scott Winston, CEO at Pulpex. “This partnership is about more than just packaging—it’s about enabling brands to meet Net-Zero targets, giving consumers sustainable choices, and helping retailers and supply chains shrink their carbon footprint.”
Smart Coatings: The Key to Performance & Sustainability
One of the biggest hurdles in paper-based liquid packaging is creating a barrier that prevents leakage while keeping products fresh. Traditional coating techniques often consume large amounts of energy and water—something SustaPack aims to change.
Professor Joseph Keddie, Royal Society Industry Fellow at the University of Surrey, explains:
“Our goal is to develop a ‘dry’ spray coating process that applies food-safe, degradable barriers without the need for excessive water or energy. This cutting-edge technology, powered by AI and mechanistic modeling, will not only transform sustainable packaging but also significantly reduce plastic pollution and carbon emissions.”
AI-Powered Precision: Eliminating Defects in Real Time
The SustaPack team is taking innovation a step further by integrating artificial intelligence (AI) and computer vision into the production process. Using thermal imaging, they aim to detect defects in wet coatings as they happen, allowing for instant corrections in real time. By combining multi-scale mechanistic modeling with AI-driven quality control, the project seeks to eliminate imperfections and achieve 100% reliability in the final product.
A New Standard for Eco-Friendly Packaging
The potential impact of SustaPack extends far beyond packaging—it’s about revolutionizing sustainable manufacturing as a whole. By optimizing materials and production methods, this initiative could set new global standards for environmentally friendly packaging, helping brands stay ahead of increasing environmental regulations while offering genuinely sustainable alternatives to consumers.
With Pulpex and the University of Surrey at the helm, SustaPack isn’t just a research project—it’s a bold step toward a plastic-free future.
