Zerocircle targets plastic-free heat sealing for paper packaging

Zerocircle has developed a heat-sealable hydrophobic coating made from natural polymers that could allow paper cups and other fibre-based packaging to achieve water and grease resistance without conventional polyethylene linings or PFAS treatments.

The material is derived from seaweed and plant-based sources and has been designed to integrate into existing paper recycling streams. Unlike conventional plastic-lined paper cups, coated packs can reportedly be repulped without requiring a dedicated separation process.

Natural polymers replace polyethylene lining

Paper cups typically require a thin plastic layer to prevent liquids and oils from penetrating the fibre structure. While effective, this additional layer can complicate recycling by creating a multi-material structure that must be separated during repulping.

Zerocircle's coating aims to provide the same functional barrier using naturally derived polymers while keeping the finished package compatible with established paper recycling systems.

The company also positions the solution as an alternative to fluorochemical treatments historically used to provide oil and grease resistance in food-contact packaging.

Heat sealing works on existing converting equipment

A key feature of the technology is its ability to form heat-sealed seams without additional adhesives.

Zerocircle says converters can manufacture coated cups using existing production equipment, reducing the need for major machinery modifications when transitioning away from polyethylene-lined structures.

The same principle could potentially be extended to other heat-sealed paper formats including wraps, sachets and pouches.

Coating withstands hot beverage applications

The material has been tested with hot liquids including boiling water and coffee and is reported to maintain functional performance at temperatures of up to approximately 90°C.

This represents an important requirement for takeaway beverage packaging, where natural barrier materials must simultaneously withstand heat, moisture and prolonged liquid contact.

Zerocircle says its materials are food-contact safe, REACH compliant and produced without harmful fluorinated chemistry.

Commercial trials target European foodservice markets

The company is preparing commercial samples for existing and prospective customers and is working with quick-service restaurants, catering operators and packaging distributors in Europe to pilot the technology.

Commercial deployment is targeted before the end of 2026 as Zerocircle moves from material validation towards larger-scale applications.

The coating is also designed to comply with requirements linked to the EU Single-Use Plastics Directive and the Packaging and Packaging Waste Regulation.

Functional coatings could simplify fibre packaging structures

The development reflects growing interest in barrier technologies that allow paper packaging to perform like plastic-lined structures without compromising fibre recovery.

For converters, compatibility with existing heat-sealing and forming equipment could be particularly important, as sustainable materials are more likely to scale when they do not require completely new production infrastructure.

If successfully commercialised, Zerocircle's natural polymer technology could provide another route towards recyclable and plastic-free foodservice packaging while maintaining the barrier and sealing performance required for hot and greasy products.