When plastic became popular in the 1950s and 60s, it quickly became a material that was both versatile and durable.

Today, plastic is recognised as one of the biggest environmental culprits. Waste enters and remains in the environment, causing pollution that harms wildlife and ecosystems - while the production of plastics causes high levels of greenhouse gas emissions.

Producing fibre-based packaging with Apple

Every year, according to the UNDP, the world produces 430 metric tonnes of plastic, a number that is expected to triple by 2060 if nothing changes, and at the same time leading to an increase in plastic pollution and greenhouse gas emissions.

Finding materials that can replace different types of plastic is therefore of high priority.

Producing fibre-based packaging with Apple

Apple, one of the world's largest companies, is working to make all of its packaging plastic-free. The tech giant has enlisted the help of RISE to develop a fibre-based material that can replace plastic.

"Together with Apple, we have developed a fibre-based foam. It has the potential to replace some of their packaging material.", says Bettina Mueller, senior project manager at RISE.

"Much of this is confidential, but I can say that we have made great progress, and I am very optimistic that this material will actually be used – and that we will be able to find even broader applications for it."

Similar process to traditional papermaking

The production of such fibre-based materials is essentially based on the methods developed for traditional papermaking.

"That is the starting point. The basic steps are then to add air and create a foam, which gives a three-dimensional structure rather than a flat paper material. Then you remove the water by dewatering and drying," says Claes Holmqvist, senior researcher in manufacturing processes for fibre-based materials at RISE.

The material could then be adapted for a wide range of applications.

"Once you find out how to make such a material, you can modify it and use it as insulation, upholstery in furniture, soundproofing in cars or filtration, for example," says Bettina Mueller.

In principle, wherever low-density plastics are used today, different types of fibre-based foams could be used instead.

Of course, the idea is not that these new fibre-based materials will end up in nature. But if they do, they will not cause the same damage as plastic.

Can be recycled like paper

"It works like paper, and paper is biodegradable. But the idea is that it should be recycled, just like paper, which also means that you don't have to use as much raw material when you produce it," says Claes Holmqvist.

The raw material in this case is the forest. The question is whether there will be enough forest if, in addition to all its other uses, it is to help replace plastic – will it be sustainable?

"We need to think intelligently about how we use these resources, where are they most beneficial? However, bio-based materials are definitely part of the solution to some of the problems we face. The cool thing about bio-based materials is that when you use resources like a tree or agricultural fibers, new ones can grow in the same place, ensuring sustainability" says Claes Holmqvist.

The transition from plastic to fibre-based materials is still in the early stages. More research and development is needed – and there are regulatory barriers, for example if the material is to be used as a building material.

Above all, however, the goal now is to reduce production costs.

"When plastic materials were new 60 years ago, they were not very inexpensive either. "It is not realistic to expect a new material to be completely equivalent and as inexpensive. You need to weigh the environmental benefits against the slightly higher costs to find a balanced approach," says Bettina Mueller.

Pilot biorefinery in Örnsköldsvik

RISE has a head start thanks to its unique understanding of the raw material - it has a long history of developing and creating new materials from wood. In the autumn of 2024, RISE will also open a new pilot biorefinery in Örnsköldsvik.

"We have the technical knowledge, but there are other things to consider when developing new materials. We mentioned sustainability and regulatory issues. We can easily bring in experts in these areas because RISE is interdisciplinary. This means that we can support the whole chain and gain a system perspective," says Claes Holmqvist.

The production, distribution and use of medical devices and medicines have a large climate and environmental footprint. The life science industry needs to do something about it.

“The keys to a green transition lie in many areas: from switching to green carbon sources and reducing material flows, to preventing toxic substances from reaching the ecosystem and making transport more efficient,” says Christina Jönsson, Vice president Marketing, division Materials and production at RISE.

As the life science industry is multifaceted, it is difficult to account for the industry's total climate impact. However, calculations show that the healthcare sector is estimated to account for 4-5 per cent of global carbon dioxide emissions. The majority, 70 per cent, comes from the supply chain, and mainly from transport. And the sector faces particular challenges. The industry is highly regulated, making circular change more difficult to implement than in many other industries.

“Just think of all the disposable items used in healthcare. They have to be of high quality, sterile and non-recyclable due to the risk of infection,” says Björn Gregertsen, Vice President, Life Science, Chemical Processes and Pharmaceutical Development at RISE.

Essential to reduce carbon footprint

Packaging that is in direct contact with medicines and sensitive medical devices - such as sampling devices - is also exempt from the EU's Packaging and Packaging Waste Regulation (PPWR) requirements on recyclability and recycled content until 1 January 2035.

"However, the EU is working intensively on sustainability issues and several other bodies regulating the life sciences industry are also reviewing their regulations. The industry itself is also driving the transition," says Christina Jönsson.

She believes that one way forward is to work much more with differentiation and gives an example:

”The tubes in IVs or catheters that go into the body should probably not be made from recycled products or be recycled. But the disposable plastic gloves that staff use might be.”

Many factors to consider for a sustainable transition

Finding the balance between stable production, economic viability and proven benefits for biodiversity and climate is a challenge.

“Us researchers can help improve understanding of what can change and contribute with relevant assessment methods and tools. This will ensure that efforts are targeted where they are needed and most effective," says Björn Gregertsen.

Reducing the carbon footprint in the pharmaceutical industry necessitates addressing various issues across the entire value chain. 

“By embracing green chemistry principles, companies can minimize harmful emissions and waste,” says Björn Gregertsen. “Additionally, adopting energy-efficient production methods and reducing reliance on fossil fuels for transportation can significantly lower overall carbon emissions. Also, addressing areas like pharmaceutical packaging will make a difference. These combined efforts pave the way for a more sustainable future in the pharmaceutical sector.”

RISE's experts can support companies that want to reduce their impact on people, the environment and the climate through this type of 'green innovation'.

“We're offering advice and circular business models in areas such as material conversion, green chemistry, pharmaceutical development and product life cycle analysis," says Björn Gregertsen.

Sustainable life sciences are the future

It can be wise to get on board with the transition right from the start. Although many of today's regulations have had exemptions for the life sciences industry and healthcare, this is likely to change.

“The issue is on the table but nothing has been decided yet on where, how and when it will be more clearly set out in legislation. But the fact that the discussion is now taking place is a signal for companies to be aware of. The life science companies that work with ecological sustainability in harmony with patient safety will gain market advantages,” says Christina Jönsson.