Page 44 - Plastics News Issue May 2025

FEATURE NEWS
troleum-based plastics more recyclable by im-
proving their surface characteristics or facilitat-
ing separation from other materials during the
recycling process.
Commercial applications and industry uptake
Over the past decade, several industries have
started integrating plant-based coatings into
their products, with food packaging being at the
forefront.
The food industry, under pressure to reduce sin-
gle-use plastic waste, has shown considerable
interest in bio-based solutions that are safe for
contact and offer effective barriers against ox-
ygen and moisture. Coated trays, cups, wraps,
and films are becoming more common on super-
market shelves.
One notable example comes from Scandinavian
packaging firms that have pioneered the use of
cellulose coatings derived from sustainably har-
vested forests. These coatings can replace con-
ventional polyethylene linings in paper cups and
cartons, which are notoriously difficult to recycle
due to their plastic-paper composition.
Cosmetic companies are also embracing this
green shift. By adopting plant-based coatings
on plastic containers, they aim to reduce micro-
plastic shedding and improve recyclability while
maintaining product integrity.
In agriculture, biodegradable plastic mulch films
coated with starch-based materials are designed
to degrade naturally in the soil, eliminating the
need for costly and labour-intensive removal af-
ter harvest.
Yet, uptake is not without its challenges. Scal-
ability, cost, and performance consistency re-
main significant hurdles. Many bio-based coat-
ings perform well under laboratory conditions
44 PLASTICS NEWS
but struggle to meet the demands of large-scale
manufacturing or harsh environmental exposure.
To overcome this, researchers and companies
are collaborating to refine formulations, enhance
durability, and streamline production methods.
The future of plastic in a circular economy
As the circular economy model gains traction
worldwide, plant-based coatings could be in-
strumental in making plastics more sustainable.
These coatings contribute to a materials eco-
system where resources are reused, waste is
minimised, and environmental damage is signifi-
cantly reduced.
One promising area of development is the inte-
gration of these coatings with recycled plastics.
Typically, recycled plastics suffer from inferior
performance compared to virgin materials, par-
ticularly in terms of moisture or gas barriers.
Bio-based coatings can help bridge this gap,
making recycled plastics suitable for more de-
manding applications such as food contact or
medical packaging.
Moreover, plant-based coatings can enable the
development of mono-material packaging—
products made from a single material type that
are far easier to recycle. In many existing pack-
ages, multi-layer constructions involve mixed
plastics or plastic-aluminium combinations that
complicate recycling. By applying a functional
bio-coating to a single plastic type, manufactur-
ers can maintain performance while simplifying
end-of-life processing.
With governments around the world implement-
ing stricter regulations on plastic usage and
waste, the role of innovative solutions like plant-
based coatings will only grow.
May 2025