Edible Packaging Films
Pinpointing and prioritizing edible-film material stacks, barrier treatments, and extrusion processes to replace single-use plastics for a global snacks manufacturer.
Client
Global Snacks Manufacturer
Objective
Identify & Rank Edible-Film Solutions
Timeline
10-Week Program
Key Focus
Moisture Resistance
The Challenge: Moving Edible Wrappers to Supermarket Shelves
Films made from starch or plant proteins can eliminate hard-to-recycle snack wraps and sachets, but moving them from artisanal concepts to mass-market products is slowed by three intertwined hurdles.
Moisture-Barrier Performance
Native starch and protein films absorb water and lose strength; coatings or cross-linkers are needed to match the performance of plastic.
High-Throughput Extrusion
High temperatures in standard extrusion lines can denature proteins and ruin the film's properties, requiring new process development.
Consumer Acceptance & Regulation
Shoppers must trust the safety of "eating the wrapper," while regulators treat the films as food ingredients, not inert plastics.
Key Outcomes: Top-Five Film Stacks
Our 6-phase program, including process modeling and SME interviews with food-regulation lawyers, delivered five leading film stacks that met the client's stringent performance, processing, and cost targets.
Cassava-Starch / PVA Blend + Beeswax Nano-coat
Achieved a water vapor transmission rate (WVTR) of 10 g/m²/day and 35 MPa tensile strength at ~$0.008 per wrap.
Pea-Protein / Glycerol Film
An allergen-free option cross-linked with genipin that is heat-sealable at 90°C and has a WVTR of 11 g/m²/day.
Alginate-Zein Bilayer
Features a hydrophobic outer face, providing a good oxygen barrier for products like nuts and chips.
Seaweed-Based Film
Reinforced with chitosan nano-fibers, this film is fully compostable if not eaten.
Strategic Impact
The snacks manufacturer green-lit a 200-kg pilot of the top-ranked cassava/beeswax film for single-serve cracker packs. Success will replace 30 tonnes of multilayer plastic per year, cut landfill waste, and position the brand at the forefront of consumer-friendly edible packaging.