Seeking Biodegradable Spray Coatings For Fiber-based Packaging

Background

As part of its PepsiCo Positive (pep+) sustainability agenda, PepsiCo is committed to reducing virgin plastic use and increasing the recyclability and compostability of its packaging. The beverage sector, in particular, presents unique challenges where durable, functional packaging must also align with environmental goals. Fiber-based packaging is a promising alternative to conventional fossil-based plastics, but requires effective barrier coatings to ensure product protection. For beverage bottles, spray applied interior coatings must deliver high barrier performance while preserving recyclability through repulping with a fiber yield greater than 85%. Current coating technologies have demonstrated limitations in meeting these combined performance and sustainability targets, prompting the need to explore biodegradable polymer resins such as PHA and similar materials. PepsiCo seeks solutions that will enable the development of fully recyclable fiber-based beverage packaging using biodegradable polymer resins, ultimately contributing to its vision of a more circular packaging economy.

Key Success Criteria

Must-Haves

• Compatible with spray coating via standard nozzle sizes
• WVTR ≤ 0.31 g/m2/day at 23°C/50% RH; water loss <1% over 6 months
• OTR ≤ 2.0 cc/ m2/day at 23°C/50% RH
• Derived from renewable resources and considered biodegradable
• Meets repulpability and fiber yield recycling requirements per the Voluntary Standard for Repulping and Recycling of Corrugated and Paper-Based Packaging (FBA/AF&PA)
• Technology readiness levels (TRL): 5-9

Possible Approaches

• PHA-based sprayable barrier coatings
• Biodegradable nanocomposite coatings
• Biodegradable resin systems
• Sprayable aliphatic polyester coatings, such as polybutylene succinate (PBS) and polybutylene adipate terephthalate (PBAT) blends
• Biopolymer crosslinked networks

Approaches not of interest

• Materials not derived from biodegradable polymer resins
• Materials containing components prohibited or flagged for food contact, or that are unlikely to meet regulatory food contact safety requirements

Preferred Collaboration types

• Sponsored Research
• Co-development

Additional Information

• Funding is proposal dependent and typically ranges from $25,000 to $100,000. Preference will be given to an integrated team that has all of the capabilities needed to develop the model.
• PepsiCo will provide access to various tools and technologies to test spray coatings and conduct barrier testing.
• Work directly with PepsiCo's team of scientists and engineers with deep experience in material science, packaging, and bringing new products to market at massive scale.