BIOWRAP

BIOWRAP: Scaling the First Industrial Flagship for 100% Paper-Based Bubble Wrap Towards a Plastic-Free Europe

Project details

Type of project: Innovation Action – Flagship
Feedstock origin: Forestry waste
Feedstock type: Cellulose

Project period: 1 June 2026 - 31 May 2031
Status: Upcoming
CBE JU Contribution: € 13 011 022,25
Call identifier: HORIZON-JU-CBE-2025

Summary

Europeans produce 16 million tonnes of plastic packaging waste each year, with under 40% being recycled. The EU’s Packaging and Packaging Waste Regulation requires all packaging to be designed for recycling by 2030, but performance, cost, and infrastructure challenges remain.

BIOWRAP aims to develop a certified 100% compostable paper-based bubble wrap alternative using patented nanocellulose fibre bonding replacing synthetic adhesives. The project will build a first-of-its-kind production facility and integrate innovations in fibre sourcing, paper formulation, coatings, and machinery to meet diverse industry needs.

This innovation directly addresses Packaging and Packaging Waste Regulation goals, enabling a scalable, circular solution to replace millions of square metres of plastic packaging, reduce marine and landfill pollution, and strengthen Europe’s sustainable manufacturing competitiveness.

Develop and optimise sustainable raw material supply chains to achieve 100% bio-based feedstock sourcing and 30% cost reduction compared to fossil alternatives.
Formulate and validate two novel bio-based coating systems that enhance barrier properties by 40%, while maintaining recyclability.
Engineer and pilot-test five fibre-based packaging prototypes, achieving performance parity with conventional packaging in 80% of targeted applications.
Design, construct, and commission a demonstration-scale manufacturing facility capable of producing continuous operation and an output of up to 17.2 million or 25.8 million square metres per year.
Establish and validate circular total life pathways achieving 90% material recovery rate through recycling, composting, or reuse.
Achieve 70% consumer acceptance rate and identify five key market segments with the highest adoption potential through comprehensive market analysis.
Implement a comprehensive safe-and-sustainable-by-design framework and achieve safety certification for all packaging products, while reducing environmental impact by 50% compared to fossil benchmarks.
Secure regulatory compliance and establish policy recommendations for three EU markets to be identified during the project.

Create a new market segment for paper-based protective packaging, replacing up to 57% of current plastic bubble wrap use cases at project completion and progressing to 100% over time.
Build an industrial-scale flagship plant proving cost competitiveness, reducing total cost of ownership for end users, and enabling replication of production sites across Europe.
Implement a licensing model stimulating cross-border technology transfer and new partnerships along the European paper and packaging value chain.
Reduce plastic packaging waste, supporting the EU circular economy targets.
Reduce CO₂ emissions per m² of packaging by 25-50% compared to plastic bubble wrap, contributing to the EU’s climate goals.
Strengthen EU industrial sovereignty in sustainable packaging, reducing dependency on imported fossil-based plastics.
Increase consumer trust and demand for sustainable packaging, supporting greener consumption patterns.