Biobased packaging from brewery waste: A PPWR-compliant solution for Europe

The BioSupPack project, funded by the European Union, has successfully demonstrated that by-products from the brewing industry can be transformed into high-performance bioplastics for sustainable packaging applications.

Over five years of implementation, the consortium has developed and validated advanced polyhydroxyalkanoate (PHA, PHB) materials and innovative production processes. These solutions provide viable alternatives to fossil-based plastics while supporting compliance with the EU Packaging and Packaging Waste Regulation (PPWR).

INTERNATIONAL COLLABORATION DRIVING INNOVATION

The BioSupPack project officially concluded with an online event bringing together 18 leading organisations across the PHA and PHB bioplastics value chain.

The project received €7.6 million in funding from the Circular Bio-based Europe Joint Undertaking (CBE JU, formerly BBI JU).

All activities were coordinated by AIMPLAS – the Plastics Technology Centre based in Valencia, Spain.

BREAKTHROUGH RESEARCH OUTCOMES

One of the key highlights of BioSupPack is its ability to convert brewery spent grains into high-purity PHB through plasma pretreatment combined with microbial fermentation. This process not only upgrades low-value waste streams but also creates industrial symbiosis between the brewing sector and the bioplastics industry.

In addition, the project has developed PHA-based coatings with up to 99% biobased content, offering full biodegradability and the potential to replace conventional materials such as PE and PVC in various industrial applications.

At the application level, BioSupPack has introduced compostable fibre-based packaging with barrier properties comparable to conventional plastics, suitable for products such as ice cream cups and food trays. Meanwhile, PHB materials have been optimised for rigid packaging applications including bottles and retail displays, meeting requirements for durability, processability, and recyclability.

Beyond material innovation, the project has also developed sorting and enzymatic recycling technologies to enhance the efficiency of post-consumer packaging waste treatment. This represents a critical step toward completing the product life cycle within a circular economy model.

TRANSFORMING THE BIOPLASTICS MARKET

According to Hasso von Pogrell, Managing Director of European Bioplastics, BioSupPack clearly demonstrates how innovation can rapidly translate into practical solutions. As PPWR drives industries to adopt more sustainable materials, the project proves that circular, biobased packaging is no longer a long-term ambition but an increasingly viable reality.

From a market perspective, the technologies developed by BioSupPack can be integrated into existing manufacturing infrastructure, significantly reducing both technical and economic barriers to adoption. This is particularly relevant as the EU targets all packaging to be recyclable by 2030, alongside increasing sustainability demands from regulators and consumers.

Furthermore, the project contributes to major European policy frameworks such as the European Green Deal, the EU Bioeconomy Strategy, and the Clean Industrial Deal. Demonstrating the large-scale production of high-performance bioplastics from industrial waste streams not only enhances resource autonomy but also opens up new value chains within the circular bioeconomy.

The results of BioSupPack are now ready for commercialisation and wide-scale adoption, targeting biopolymer producers, biorefineries, packaging manufacturers, as well as brands in the food, cosmetics, and consumer goods sectors.