Sustainable materials and processes design: the case study of Poly-Paper

Polymeric materials used for packaging have unsolved environmental sustainability problems. The ideal packaging must be recyclable and/or compostable, with a unique recycling channel. This is focused on the development of an innovative eco-composite material based on water-soluble polymeric matrix reinforced with cellulose fibers up to 60 % w/w: Poly-Paper. The material can be processed by conventional processes of thermoplastics (extrusion, thermoforming, injection moulding, 3D printing) and can be recycled together with paper-based materials. This work describes the innovative expanded version of Poly-Paper and the developed forming technology: Water Shaping, able to give the material a great impact and energy absorption capacity in packaging applications.