Thermoformed fibre for sustainable 3D packaging with barrier coatings
Innovative cellulose fibre packaging with bio-derived coatings offers high barriers to oxygen and water vapour, ensuring sustainability and recyclability. Ideal for food, pharmaceutical, and nutraceutical packaging, this solution is compostable and paper-recyclable.
Overview
Our solution presents a cutting-edge approach to sustainable packaging through the use of thermoformed cellulose fibres combined with bio-derived and biodegradable coatings. This innovative material provides excellent barriers to oxygen and water vapour, making it ideal for packaging applications that require protection from environmental factors. By avoiding conventional plastic laminates, our materials are fully recyclable within paper waste streams and certified as home compostable. This makes them particularly attractive for food, pharmaceutical, and nutraceutical packaging.
Technical specifications
- Materials: Cellulose fibre structures sourced from both non-tree waste fibres and tree fibres.
- Coatings: Custom polymer blends developed in-house, certified for home compostability and food-contact safety with both dry and liquid simulants.
- Applications: Suitable for 3D packaging forms such as blister packs, with the potential for additional tool and process development.
- Sustainability: Fully recyclable in paper waste streams, avoiding the recycling challenges associated with plastic laminates.
Technology readiness level
This technology is at TRL 5, indicating that it has been validated in a relevant environment. Our future plans include further exploration of market opportunities and collaboration for coating applications on various packaging forms.
About Varden Process Pty Ltd
Varden Process is a Melbourne-based technology and intellectual property company that develops sustainable, plant-based packaging solutions designed to replace plastic and aluminium in the consumer goods market. The company engineers advanced manufacturing systems that process post-agricultural waste, such as sugar cane or wheat straw, into high-performance moulded fibre products. Their proprietary technology combines precise tooling designs, sophisticated fibre refining, and custom bio-polymer coatings to create packaging with superior barrier properties against oxygen and water vapour. These materials are designed to be home-compostable and recyclable while maintaining the structural performance required for high-speed automated filling lines and global supply chains.
This technology addresses significant environmental challenges by reducing the reliance on virgin timber, fossil-fuel-based plastics, and metal packaging that contribute to global waste and pollution. Varden's solutions are particularly relevant for industries requiring high-standard preservation, such as coffee, pharmaceuticals, and perishable foods. By offering a sustainable alternative that integrates seamlessly into existing industrial processes, the company helps brands achieve their environmental commitments and comply with increasing global legislation regarding plastic usage. Backed by venture capital, Varden continues to innovate through its internal research and development, holding numerous patents related to capsule geometries and material science.
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