Caco3-based sustainable packaging box for frozen food replacing EPS

Overview

This solution offers a calcium carbonate (CaCO3)-based packaging box designed to replace expanded polystyrene (EPS) containers used in frozen food logistics. The packaging addresses growing sustainability and recycling requirements by combining 70% CaCO3 with 30% polyethylene (PE), creating a reusable, recyclable, and waterproof container suitable for perishable and frozen products. The integrated system covers the full lifecycle of the box, including use, reuse, washing, sanitization, and recycling, enabling seamless adoption within existing frozen food handling and maintenance operations.

Technical specifications

• Material composition: 70% calcium carbonate blended with 30% polyethylene, with potential substitution of PE by biopolymers such as PLA or PHB to further reduce carbon footprint.
• Thermal conductivity: 0.04 W/m°C, comparable to conventional air-based insulations including cellulose and EPS (0.036–0.048 W/m°C).
• Design features: Flat-packed configuration for space-efficient storage and reduced warehouse costs; lower thickness compared to EPS, enabling up to 42% reduction in freight costs.
• Performance validation: Lab-scale testing demonstrated that whole red sea bream stored in CaCO3-based containers under non-isothermal simulated transport conditions maintained similar microbial load (TVC 7.8–8.0 logCFU/g) after 11 days compared to EPS boxes of similar dimensions.
• Safety evaluation: Containers have been assessed for total and specific migration and cytotoxicity using chemical analysis and cytological methods.

Technology readiness level

The technology has been validated at proof-of-concept scale with demonstrated thermal insulation performance and food safety compatibility. The project targets immediate or near-immediate implementation at TRL 8–9, with planned systematic validation across temperature ranges from -5°C to -50°C under recommended, realistic, and abuse cold chain conditions. Future work includes evaluating reusability through microbiological and chemical analysis, optimizing washing and sanitization protocols, and conducting life cycle analysis to quantify environmental benefits relative to conventional EPS packaging. Project duration is 12 months.