Finland’s VTT Technical Research Centre and LUT University have reported progress in the development of fully cellulose-based films and coatings that could reduce the use of plastic in packaging while maintaining industrial performance. The work was carried out under the F3 – Films for Future bio-based materials project, which was completed in March 2026 after demonstrating pilot-scale production across several packaging applications.

The project focuses on one of the packaging industry’s most difficult challenges: replacing plastic films without losing transparency, strength, barrier performance or compatibility with existing converting processes. Plastic films are widely used because they are light, flexible and protective, but they are also among the hardest formats to recycle, especially when used in multilayer structures or contaminated after use.

The F3 platform approaches cellulose in a different way. Instead of treating it only as a fibre, researchers have developed methods that allow cellulose to be processed as a polymer through dissolution and regeneration. This has enabled the production of transparent film materials with mechanical and barrier characteristics closer to those expected from conventional plastic packaging.

The key achievement is not simply making a bio-based film, but creating cellulose materials that can work with real packaging machinery, recycling systems and biodegradation pathways.

The films are designed to be biodegradable, while the coatings can be tailored either for recycling in fibre-based systems or for biodegradation where required. This flexibility is important because end-of-life requirements differ by application. Some packs need to move through paper recycling streams, while others may require biodegradability in specific use cases where collection is difficult.

The work is especially relevant as regulations such as the EU Packaging and Packaging Waste Regulation place stronger pressure on recyclability, material content and lifecycle impact. Packaging producers are increasingly looking for materials that can reduce fossil-based plastic use without creating new problems for processors, recyclers or consumers.

According to the project team, the cellulose platform has already shown compatibility with established converting processes, including thermoforming. This is a crucial step because commercial adoption depends not only on material properties, but also on whether converters can run the material on existing or adapted production lines without excessive cost, downtime or waste.

• Transparent films: cellulose-based materials could support visible packaging where product presentation matters.
• Barrier coatings: fibre-based packs can gain oxygen and grease protection while remaining recyclable.
• Functional packaging: future versions may include antimicrobial, antioxidant or responsive features.

Performance data from the project is promising. For films, the oxygen transmission rate was reported below 1cc/m²/day at 23°C and 50% relative humidity, a level described as comparable with conventional plastics. For coatings, the oxygen transmission rate was below 0.2cc/m²/day, while grease barrier performance reached KIT 12 in recyclable fibre-based packaging systems.

These results suggest potential early applications in dry food packaging, bakery products and fibre-based packaging that requires transparent barrier layers. Such applications could allow brands to reduce plastic content while keeping the visibility and protection needed for retail presentation and shelf life.

The platform may also extend beyond direct plastic replacement. Researchers see potential in coatings with antimicrobial or antioxidant properties, as well as packaging that can respond to humidity, gas composition or pH. This points toward smarter cellulose-based materials that combine sustainability with active or intelligent packaging functions.

VTT research professor Ali Harlin said cellulose materials open new sustainable solutions for packaging, while also helping manufacturers meet evolving regulatory requirements without compromising product protection, shelf life or process efficiency. LUT University’s Ville Leminen also highlighted that the materials have already demonstrated processability in different package converting processes.

The next stage will focus on scaling the technology for commercial use and improving performance under humid conditions. Moisture remains a critical challenge for many fibre-based and bio-based materials, particularly in food packaging where barrier stability must be maintained across storage and distribution environments.

For the packaging sector, the F3 project represents a significant step toward cellulose-based alternatives that are not only renewable, but technically credible. If successfully scaled, these films and coatings could help brands move away from hard-to-recycle plastic films while supporting circular, fibre-based and biodegradable packaging routes.

Image concept: a Finnish packaging research laboratory showing transparent cellulose films, recyclable coated paperboard samples, pilot-scale film production equipment and dry food packs using bio-based barrier layers.