Recyclable high-barrier flexible packaging for OTC wellness products
Innovative recyclable packaging solution using cellulose-based substrates and bio-based coatings to achieve ultra-low moisture and oxygen permeability for OTC wellness products, compatible with existing packaging lines and aligned with recyclability standards.
Overview
The proposed solution offers a groundbreaking approach to flexible packaging for over-the-counter (OTC) wellness products by utilizing recyclable cellulose-based substrates reinforced with bio-based polymer coatings. This innovative design integrates nanocellulose and water-based biodegradable coatings to create a high-barrier packaging solution that minimizes the use of virgin plastics and reduces carbon footprint. By achieving ultra-low moisture vapor transmission rates (MVTR) and oxygen permeability, the packaging ensures product stability and longevity while aligning with APR/RecyClass recyclability guidelines.
Technical specifications
Key features:
- Advanced material integration: Utilizes cellulose substrates, nanocellulose, and bio-based coatings for high-barrier performance.
- Barrier performance: Achieves ultra-low MVTR (<0.1 g/m²/day) and oxygen transmission rates, validated under ASTM standards.
- Compatibility: Designed for use with existing form-fill-seal (FFS) lines at 120–200°C, ensuring seamless integration into current manufacturing processes.
- Recyclability: Mono-material approach simplifies end-of-life management, enhancing recyclability.
Applications:
- Suitable for biomedical and OTC packaging, providing protection against moisture and oxygen while ensuring regulatory compliance.
Technology readiness level
Currently at TRL 4, this technology has undergone validation for its barrier properties and recyclability. Future development includes further material selection, optimization of film architecture, and lifecycle analyses to ensure commercial feasibility and environmental sustainability.
About Michigan State University
Michigan State University is a major public land‑grant research university with a comprehensive academic portfolio and a large research enterprise. Industry partners engage through an on‑campus U.S. Department of Energy national user facility and shared core laboratories with user access. The university provides a chemical process scale‑up pilot plant on Michigan’s lakeshore, a research and technology park, and a Grand Rapids health innovation campus linking researchers with clinical partners. A statewide extension network supports field deployment and workforce training across Michigan’s manufacturing corridor. Research is backed by competitive federal funding from NSF, NIH, DOE, USDA, and DoD, while dedicated tech transfer and corporate engagement teams—supported by an affiliated research foundation—accelerate IP, licensing, startups, and sponsored research.
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