Biosurfactant coatings as recyclable barrier materials for food packaging
Hydrophobin-based protein coatings that replace PFAS in food packaging, offering superhydrophobic water repellency and oxygen barrier properties. These biocompatible, recyclable biosurfactant coatings enable streamlined recycling with fewer sorting steps while delivering performance comparable to conventional fluoropolymer-based barrier materials.
Overview
This solution leverages hydrophobin, a naturally occurring protein with remarkable water-repellent properties, to create superhydrophobic coatings for food packaging. When adsorbed onto surfaces, hydrophobin forms a barrier that repels water (contact angle exceeding 150 degrees), withstands boiling and harsh processing conditions, and restricts oxygen transport. As a protein-based biosurfactant, hydrophobin offers a green, biocompatible alternative to PFAS and other fluoropolymer coatings currently used in food packaging. Because it is inherently compatible with existing recycling streams, hydrophobin coatings can simplify recycling processes by reducing the need for complex material sorting steps, supporting circular packaging initiatives and regulatory compliance around PFAS restrictions.
Technical specifications
Key features:
- Superhydrophobic surface formation: Hydrophobin adsorbed onto plastic, glass, or fiber surfaces achieves water contact angles greater than 150 degrees, matching the performance of conventional fluoropolymer coatings
- Oxygen barrier capability: The protein self-assembly restricts oxygen transport across coated substrates, a critical property for preserving food freshness and shelf life
- Processing durability: Coatings remain stable and functional through boiling and other harsh processing steps commonly encountered in food packaging applications
- Tailorable properties: A proprietary platform enables rapid production and screening of hydrophobin variants to customize surface wettability and oxygen transfer rates for specific substrates (paper, fiber, plastic)
- Scalable production: Robust fermentation and bioprocessing platforms support commercial-scale manufacturing of hydrophobin biosurfactants
- Demonstrated incorporation: Validated performance on paper substrates ranging from 22 to 280 gsm
Validation methods:
- Oxygen transmission measured via ASTM F3136 and an electrochemical oxygen detection chamber under controlled humidity conditions
- Water vapor transmission assessed using ASTM E96 standards
- Hydrophobicity engineered through systematic variation of protein hydrophobicity to identify optimal coating formulations
Technology readiness level
The technology is at an advanced stage of development, supported by multiple peer-reviewed publications demonstrating hydrophobin self-assembly, surface hydrophobicity, and scalable production. Prior collaborations with Merck have validated the ability to tailor hydrophobin properties for specific interface applications. The proposed work focuses on validating hydrophobin coatings on industry-preferred paper substrates supplied by Sunoco, using standardized ASTM testing protocols for oxygen and water vapor barrier performance. The platform for rapid biosurfactant production and property tuning is established, positioning the technology for pilot-scale demonstration and partnership with packaging manufacturers seeking PFAS-free barrier solutions.
About Lytos Technologies, Inc.
Lytos Technologies is a biosolutions platform company that engineers biology to address persistent challenges across water, food, agriculture, and health sectors. The company utilizes its proprietary LytosBI platform, which integrates computational modeling, data-driven design, and molecular biology, to develop technologies that dismantle biofilms and neutralize microbial pathogens. By focusing on fundamental biological mechanisms, Lytos creates targeted alternatives to traditional chemical approaches, aiming to provide solutions that are safer, more sustainable, and capable of performing in complex real-world environments. The company's core scientific foundation stems from research into novel anti-biofilm enzymes, which allow for the advancement of laboratory-validated innovations into scalable, field-ready biosolutions.
The company collaborates with industry, government, and institutional partners, such as the USDA and the University of Virginia, to translate scientific breakthroughs into practical applications. This partnership-driven approach ensures that their developments meet specific real-world requirements for performance, safety, and deployment. By replacing or enhancing conventional chemical methods with biological intelligence, Lytos seeks to resolve critical issues ranging from crop yield protection and food safety to environmental contamination, helping customers and stakeholders manage risks in diverse operating conditions. Through its efforts, the company aims to foster a healthier and more sustainable future by expanding the capabilities of engineered biology.
delivered to your inbox.