VTT Technical Research Centre of Finland and LUT University have made substantial progress in developing fully cellulose-based film and coating materials through the F3 – Films for Future project, a collaborative research initiative focused on bio-based materials for the packaging industry. The results demonstrate that cellulose-based film in packaging can deliver plastic-comparable performance while meeting end-of-life requirements such as biodegradability and recyclability within fibre-based systems.
The technology enables cellulose to be processed as a polymer rather than a fibre, resulting in transparent films with mechanical and barrier properties comparable to those of conventional plastics. The films are inherently biodegradable, while the coatings are engineered to support both recyclability within fibre-based packaging systems and biodegradability where applicable. The development comes against the backdrop of tightening regulation, including the EU Packaging and Packaging Waste Regulation (PPWR), which is increasing requirements around recyclability, material composition, and lifecycle impact.
“Plastic films are one of the most widely used packaging formats, yet they are among the most difficult to recycle and a major source of persistent environmental pollution,” said Ali Harlin, Research Professor at VTT and one of the leading coordinators of the F3 project. “At the same time, we are working with manufacturers to help them meet evolving regulatory requirements while maintaining product protection, shelf life, and process efficiency. Cellulose materials open new sustainable solutions for packaging.”
The F3 material platform is designed to integrate with existing converting technologies and fit within current recycling streams or biodegradation pathways depending on the application. Unlike many bio-based alternatives, it avoids the typical trade-off between functionality and end-of-life handling. The project builds on advances in cellulose dissolution and regeneration, enabling films with high transparency, mechanical strength, and barrier properties. Processing compatibility has been demonstrated with conventional industrial methods such as thermoforming, supporting integration into existing manufacturing infrastructure.
“The cellulose films and coatings have already been demonstrated to have the properties to be processed in various package converting processes, which highlights their future potential,” said Ville Leminen, Professor of Packaging Technology at LUT University and leader of LUT’s sub-project.
Carl-Erik Guttormsen, Area Director at Colombier Finland, highlighted the commercial readiness of the technology: “Finding the right balance between functionality and sustainability is critical for the future of packaging. Through the F3 project, we have bridged this gap by developing fully plastic-free barrier coatings that deliver high performance without ecological compromise. Utilizing our off-line coating line, we are now able to commercialize these solutions on paper and board for demanding food packaging applications.”
Completed in March 2026, the F3 project demonstrated the feasibility of producing cellulose-based packaging materials at pilot scale across multiple applications. For films, the results confirm potential as a standalone, transparent packaging material with inherent biodegradability. Measured oxygen barrier performance for films was below 1 cc/m²/day (OTR at 23°C and 50% RH), which is comparable to conventional plastic films. For coatings, the technology achieves an oxygen transmission rate below 0.2 cc/m²/day and a grease barrier rating of KIT 12, enabling high-performance barrier layers within recyclable fibre-based packaging systems.
“The key challenge has not been whether alternative materials exist, but how to process them in a way that meets industrial requirements,” said Vinay Kumar, Senior Scientist at VTT. “What has now been demonstrated is a future-ready material platform that offers an alternative to plastics, combining sustainability with the capability to integrate into existing manufacturing and recycling systems. We see strong potential to develop this further together with industry partners.”
Riku Talja, Development Manager at Metsä Board, reinforced the importance of system compatibility from an industry standpoint: “From an industry perspective, scalability and system compatibility are critical factors. Solutions that align with current converting technologies and recycling infrastructure are far more likely to transition from pilot-stage innovation to industrial use.”
The next phase of development will focus on scaling the technology toward commercial applications, with initial use cases identified in dry food packaging, bakery products, and fibre-based packaging requiring transparent barrier layers. Further work will target barrier performance under humid conditions and the integration of multiple functionalities within a single material system.
The platform also carries potential for multifunctional applications, including antimicrobial or antioxidant functionality and environmentally responsive packaging capable of reacting to humidity, gas composition, or pH capabilities increasingly relevant as packaging technology advances toward active and intelligent systems. Digitalisation, including sensor-enabled or connected packaging, is expected to play a role in future applications as well.
Mats Berg, Sr Principal Scientist, Discovery & Innovation at Kemira, emphasised the importance of broader industry adoption: “Value chain adoption of these platforms is essential for the ongoing transition towards fully renewable and recyclable technologies. We see chemistry as the key enabler for this transition.”
Beyond packaging, the material platform has potential applications in medical materials, electronics, and functional coatings, reflecting the wider role of cellulose as a renewable and versatile polymer in future material systems.
The F3 project involved collaboration between research organisations, industry partners, and funding bodies, with 34 industrial partners participating in total. The programme was funded by the European Regional Development Fund (ERDF). The work focused on advancing sustainable packaging technology from laboratory development toward scalable manufacturing, aligned with VTT’s broader mission to accelerate sustainable growth and support companies in scaling new technologies that contribute to the green transition.
