Co-funded by MIMIT, this project has led to the development and testing of a natural fiber dry molding technology, broadening the scope for the manufacture of sustainable, recyclable packaging solutions.
Transforming natural fibers into new packaging solutions: this is the central challenge of FIBER-CAP, a SACMI research and development project funded by the Italian Ministry of Enterprises and Made in Italy (MIMIT) via the ‘Agreements for Innovation’ investment tender.
The project is part of advanced research and prototyping efforts by the SACMI Rigid Packaging Lab, which focuses on developing technologies for sustainable rigid packaging and exploring the potential of paper-based biomaterials.
FIBER-CAP aligns with a SACMI innovation strategy that seeks to make the most of development opportunities in high-potential sectors by focusing on sustainability and developing new materials and production processes. In this context, the project has led to the establishment of the SACMI Dry Molding Line, an automated pilot line for the dry molding of caps, closures and other components made of cellulose-based material.
This marks the transition from experimentation to a technology that’s been tested for industrial use and is able to produce finished, ready-to-use components. Specific validation tests have confirmed the quality of the product, the stability of the process and the soundness of the line. The technology has also demonstrated a capacity to handle various materials and formats flexibly.
At the core of FIBER-CAP lies a resource of immense potential: cellulose. Nature’s most abundant bio-polymer, it is both compostable and fully recyclable through the traditional paper recycling stream. In collaboration with Italian/international universities and major food companies, SACMI has already developed and tested caps and closures using this material.
One of the key features of the technology is dry molding. As the name suggests, this eliminates the use of water. It also delivers shorter cycle times compared to alternative technologies and is more energy-efficient. Furthermore, specific technical solutions ensure the material is properly compacted, also along the side walls, paving the way for the manufacture of complex shapes.
This project opens up new prospects for more sustainable packaging. Depending on the specific item, caps (and various other rigid packaging items, such as single-serving containers, coffee capsules and lids) made from natural fibers can be disposed of via paper recycling or organic waste collection streams. The technology can also draw on materials sourced from paper and cardboard recycling chains.
Thanks to support from MIMIT, the project has successfully transitioned from industrial research and experimental development into a technology that's ready for industrial use. The result: more options for the industry to produce sustainable, natural fiber-based packaging.