Biodegradable & Compostable Rigid Containers
Mapping material-coating stacks and certification pathways for a multinational FMCG brand to deliver PET-like performance with clear compostability claims.
Client
Multinational FMCG Brand
Objective
Identify & Rank Rigid Container Solutions
Timeline
10-Week Sprint
Key Focus
Compostability & Performance
The Challenge: Three Industry-Wide Hurdles
Moulded-fibre trays and PLA composites promise to replace petroleum-based PET and HDPE containers, but their vision collides with three major hurdles.
High-Humidity Performance
Fibre and PLA lose stiffness and burst strength above 60% RH, requiring advanced coatings to maintain puncture energy and structural integrity.
Composting Infrastructure Variability
Many regions lack industrial composting facilities, and achieving "home-compostable" certification requires rapid disintegration at low temperatures.
Label Confusion & Consumer Trust
Shoppers and brands often muddle "biodegradable" and "compostable," leading to greenwashing scrutiny and costly recalls.
Key Outcomes: Top-Five Material Stacks
Our 5-phase sprint produced a shortlist of five material stacks that deliver PET-like performance and have a clear certification pathway.
- Bagasse / 20% PLA Core + AKD Nano-emulsion Coat: Passes industrial compost tests in 9 weeks with 93% flexural strength retention.
- Bamboo-Fibre + PHBV Binder, Shellac Over-coat: Achieves 90% mass loss in 20 weeks in home compost simulations.
- Recycled OCC-PLA with Bio-Wax Dispersion: Offers the lowest carbon footprint, 38% lower than virgin PET.
- Seaweed-Cellulose Foam Board: The lightest weight option, though it requires new tooling.
- Pulp-Mould + Protein-Cross-Link Finish: Provides excellent microwavability for food service applications.
Economic & Messaging Insights
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Economic Viability: All five shortlisted stacks beat 5-year LCOE parity with PET under existing EU plastics tax scenarios.
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Messaging Insights: Consumer testing revealed that the phrase “Industrial-compostable, not backyard” with a QR-code explainer reduced confusion by 58%.
Strategic Impact
The FMCG brand approved a 1-tonne pilot of the top-ranked Bagasse/PLA stack for its yogurt cup line. Success will position the company to eliminate 1,800 tonnes of PET per year, meet upcoming EPR fees, and offer shoppers a clear, trustworthy compostable option.