Key enabling manufacturing technology for low-cost and sustainable production of fibre-based rigid packaging at scale

Plastic is widely known as one of the most significant and rapidly growing sources of industrial waste, with the EU alone estimated to generate 25.8 Mt of plastic waste every year (58 kg/person). Packaging is the main use of plastic, accounting for 60 % of the total plastic waste in the EU.

Worldwide, governments are prohibiting and taxing the use of single-use plastics, setting high pressure on the packaging industry to shift to sustainable materials.

Cellulose (fibre-based) materials are a promising alternative that can replace plastics in most of rigid packaging products in a 1:1 ratio without compromising quality.

However, the high costs of their current production processes have prevented packaging producers and brands from substituting plastics with fibre-based materials at a commercial scale.

The Loop Factory has developed Yangi, the world’s first manufacturing machine to unlock a true substitute to plastic in rigid packaging: low-cost, 3D fibre-based packaging production at scale.

At the heart of its innovation there is an efficient process consisting of one-step production line that consumes considerably less resources and time than existing two-step production methods. In comparison, Yangi uses 85% less water which minimises the energy needs with 75%. This allows for a faster, cheaper and scalable production claiming 80% less factory space and half of machinery costs.

Yangi makes it possible for cellulose to finally compete with plastics in low-cost, high volume segments.

The EIC accelerator project will setup a demonstration plant to run customer pilots in 4 packaging applications and show their results to additional stakeholders.

We will establish a scalable manufacturing and distribution partnership with a global machine supplier and secure IP for market release and scale up.

With 77 machines in operation by 2030, our technology is expected to save more than 190 000 tons of plastic waste, 11 Bn litres of fresh water and 260 000 tons of CO2.