Protein-based sustainable foam alternative for packaging applications
A novel technology that transforms structural proteins like gelatin into lightweight, closed-cell foams via microwave or thermal processing. Offers a low-cost, compostable alternative to traditional petroleum-based packaging foams with densities comparable to aerogels.
Overview
This technology offers a sustainable, low-cost alternative to conventional petroleum-based packaging foams by using physically cross-linkable structural proteins such as gelatin and gelatin alternatives. Dehydrated protein films can be expanded into lightweight foams through controlled exposure to heat or microwave radiation, producing closed-cell structures with high porosity and densities comparable to aerogels. The result is a compostable packaging material that addresses growing demand for environmentally responsible alternatives in the packaging industry.
Technical specifications
- Feedstock: Hydrophilic structural proteins including gelatin and identified gelatin alternatives
- Processing methods: Microwave radiation or temperature-driven evaporation (~100°C) applied to dehydrated protein films
- Foam properties: Closed-cell pore morphology, 100% macroporosity with pore sizes ranging from 332 to 1700 μm, external skin formation
- Density: Approximately 0.039–0.056 g/cm³, comparable to aerogels
- Porosity: Greater than 94%
- Future development: Testing of at least three food-grade coatings to improve strength, heat resistance, water resistance, and compostability
Technology readiness level
The core foaming process has been validated through laboratory fabrication of gelatin foams demonstrating the desired closed-cell morphology, high porosity, and low density. Prior published work (Frazier and Srubar, 2016; Frazier, Aday, and Srubar, 2018) establishes proof of concept. The technology is currently at an early-to-mid stage, with ongoing efforts focused on benchmarking mechanical strength, thermal stability, water resistance, and compostability, followed by coating optimization to meet commercial packaging performance requirements. The team is actively seeking funding and commercialization partnerships to accelerate development toward market readiness.
About University of Colorado, Boulder
The University of Colorado Boulder is a comprehensive public research university serving a large student body and a broad portfolio of scholarship. Corporate partners tap co-located federal research laboratories and shared-use core facilities, with collaborations supported by an on-campus research and technology park. Proximity to the Boulder–Denver innovation corridor and strong regional aerospace and photonics clusters provide access to suppliers, testbeds, and experienced talent. Research is supported by competitive federal funding, including awards from NSF, NIH, DOE, NASA, and DoD. A dedicated technology transfer office streamlines IP strategy, licensing, and startup formation, with incubator and accelerator programs connecting companies to faculty and student talent.
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