Sustainable aluminum-free multilayer packaging alternative for food applications
SAFR PAK is a sustainable, aluminum-free packaging solution designed to replace aluminum-based packaging in food applications. It uses commercially available metalized biodegradable or recyclable multilayer structures to deliver oxygen and water barrier performance, along with mechanical strength and stiffness for forming, filling, and sealing. The approach targets compliance with relevant performance testing standards and is suitable for high-temperature processing.
Overview
SAFR PAK is an aluminum-free packaging solution intended to replace conventional aluminum foil-based packaging in food applications, including dairy products. The approach uses commercially available metalized biodegradable or recyclable multilayer packaging structures to provide oxygen and water barrier performance. The solution is designed to meet industry performance requirements for structural integrity, dead fold, and stiffness at higher temperatures, supporting forming, filling, and sealing in commercial manufacturing environments.
Technical specifications
Key features:
- Biodegradable or recyclable multilayer structure
- Oxygen and water barrier properties meeting industry standards (e.g., OTR ≤ 0.15 cc/m² per day)
- Mechanical properties including puncture resistance (>75 N load at break) and stiffness at elevated temperatures
- Compliance with ASTM D1469 Standard Practice for performance testing
- Suitable for food packaging applications requiring high-temperature processing
Technology readiness level
SAFR PAK is currently at Technology Readiness Level 4. Laboratory validation has been completed, and additional testing is planned. The research plan includes evaluating three sustainable packaging structures against a control for critical performance metrics. Future validation steps include mechanical property testing at elevated temperatures and recyclability assessments, with results intended to be shared with industry stakeholders.
About University of Massachusetts Lowell
UMass Lowell is a comprehensive public research university in the University of Massachusetts system, known for hands-on, industry-aligned education. Industry partners engage through open-access core research facilities and pilot-scale labs for prototyping and scale-up, supported by staff for contract services. A robust co-op program connects companies with student and faculty talent, while incubator and coworking sites near campus offer labs and flexible space. Research is supported by competitive federal funding from agencies such as the National Science Foundation, National Institutes of Health, Department of Energy, and Department of Defense. A dedicated technology transfer office supports IP, licensing, sponsored research, and startup formation to streamline commercialization.
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