Flexible biopolymer barrier films and coatings using nanocellulose and chitosan
Flexible biopolymer films and coatings designed for high-performance packaging, combining transparency and flexibility with strong oxygen and water vapor barrier performance. The technology uses nanocellulose and chitosan and is evaluated for recyclability and compostability, including semi-industrial testing and ongoing work to improve water vapor transmission in compostable paper-coated systems.
Overview
Flexible biopolymer barrier films and coatings developed using nanocellulose and chitosan provide transparent, flexible materials with barrier performance against oxygen and water vapor. The technology is tested on a semi-industrial scale for recyclability, including assessment of mechanical properties with biopolymer integration. Current development focuses on improving water vapor transmission rates (WVTR) in compostable paper-coated systems.
Technical specifications
- Materials Used: Nanocellulose, chitosan, polyethylene (PE)
- Layer Configuration: PE 23µm / “CSP09” 5µm / PE 23µm
- Barrier Properties:
- Oxygen Transmission Rate (OTR): 0-0.1 cc/m2/day (significantly lower than PE alone)
- Water Vapor Transmission Rate (WVTR): 2-2.5 g/m2/day (improved from PE alone at 5 g)
- Recyclability: Fully recyclable with contamination levels under 10%
- Compostability: Development ongoing for fully compostable paper-coated systems with improved WVTR
Technology readiness level
Currently at Technology Readiness Level 4, the solution has been validated in a laboratory setting and is undergoing further development and testing to refine and optimize water vapor barrier properties. The project aims to prepare for semi-industrial trials within the next 6-12 months.
About Cambridge Smart Plastics Limited
Cambridge Smart Plastics is a research-intensive technology company that designs novel polymer compounds with unique material properties to improve the performance and sustainability of industrial products. Founded as a spin-out from the University of Cambridge, the company leverages expertise in dynamic covalent bonding, "vitrimers," and polymer chemistry to create materials that are reprocessable, remouldable, and recyclable. Their proprietary technologies include Mesodamp, a liquid crystal elastomer engineered for high-performance damping, and advanced biopolymer solutions—such as nanocellulose-based barrier films—designed to replace non-recyclable metal or chlorinated plastic coatings in packaging. By bridging the gap between academic innovation and commercial application, the company provides bespoke material development and consultative services to sectors including automotive, aerospace, and consumer goods.
The company's work addresses critical industrial challenges, such as the need for more efficient waste recovery and the demand for sustainable, plastic-free packaging alternatives. By focusing on circular economy principles, their technologies allow for the development of thermosets with shape-memory capabilities and improved recyclability, effectively reducing environmental impact. Through industrial trials and partnerships, Cambridge Smart Plastics aims to scale its advanced polymer technologies to move industries toward greener, high-value manufacturing standards. Their efforts are supported by a leadership team comprising commercial and academic expertise, operating from facilities associated with the University of Cambridge to translate complex polymer science into practical, scalable solutions for partners and customers.
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