Researchers at Georgia Tech have developed a new type of biodegradable, plant-based packaging using natural fibers such as chitin and cellulose, offering an innovative and sustainable alternative to traditional plastic packaging. The research, led by Professor Carson Meredith and his team of students, began with a serendipitous discovery during an experiment with a type of white beetle found in Southeast Asia. The beetle’s exoskeleton is made from chitin, which inspired the team to explore its potential use in packaging materials.

The team initially focused on using chitin, a carbohydrate commonly found in crab and lobster shells, to mimic the beetle's brilliant color. However, when the team experimented with chitin nanofibers from crab shells, they unexpectedly discovered that the material formed dense, transparent films. When tested for oxygen barrier properties, the films exhibited impressive resistance, outperforming many conventional packaging plastics. This surprising result shifted the focus of the research from color to packaging, with the aim of creating a biodegradable film that could be used as an alternative to single-use plastic packaging.

Since that breakthrough in 2014, the Georgia Tech team has worked tirelessly to scale up the technology, ultimately combining chitin with cellulose nanomaterials – another carbohydrate polymer obtained from plants. The combination of these materials created a barrier film with superior performance in terms of both moisture and oxygen resistance. The cellulose and chitin layers, when applied using a spray coating technique, bond due to their opposite electric charges, creating a dense, high-performance interface.

In 2024, further advancements led to the discovery that carboxymethylcellulose, a food ingredient, when combined with citric acid, could resist water vapor and moisture, another key challenge for packaging materials. The result was a bio-based film that not only resisted moisture but also performed exceptionally well in blocking oxygen, making it a promising alternative to plastics.

The team’s most recent achievement, in 2025, merged these innovations into a bio-based film that is biodegradable, compostable, and highly resistant to both oxygen and moisture. These films, when cast into thin layers, form a dense structure that resists swelling in humid conditions, maintaining their integrity even in environments with up to 80% humidity. Tests showed that the new film matched or exceeded the performance of conventional packaging plastics, making it a viable, eco-friendly option for sustainable packaging solutions.

One of the key challenges in scaling up production is the limited availability of bio-based components compared to the mass production of plastics. As the demand for bio-based materials grows, this challenge will likely be addressed through increased supply chain development, similar to what occurred in the early days of plastic production. The team is currently working with industry partners to incorporate these films into existing packaging lines, utilizing scalable roll-to-roll coating techniques for mass production.

In addition to technical innovations, the regulatory landscape plays a critical role in the adoption of sustainable packaging materials. As governments introduce stricter regulations on single-use plastics, and companies set sustainability targets, bio-based films could become a major part of the solution to global plastic pollution. This breakthrough in plant-based packaging materials highlights the potential of natural fibers to address one of the most pressing environmental challenges of our time: reducing plastic waste and dependence on non-renewable resources.

The research team at Georgia Tech continues to explore ways to scale production and integrate these materials into the broader packaging market. With ongoing work and patent filings, this biodegradable packaging could soon become a reality on store shelves worldwide, contributing to a more sustainable and eco-conscious future.