Sustainable Eucalyptus globulus moulded cellulose as an alternative for fossil-based food packaging

The Navigator Company is a leading integrated producer of forest-based bioproducts and a global marketer of pulp and paper products, with a diversified portfolio that spans kraft pulp, UWF paper, tissue paper, renewable energy and, since October 2024, moulded cellulose packaging. Headquartered in Setúbal, Portugal, the company operates 10 industrial units across Portugal, Spain, and the UK, and manages FSC and PEFC certified forests in Portugal, Spain, and Mozambique. Navigator owns global brands such as Navigator and Pioneer,

The project began by demonstrating the suitability of Eucalyptus globulus fibre for thermoforming technology. It then advanced to the development of barrier property solutions tailored to this fibre, along with the creation of products for food contact applications. In parallel, the 1^st factory was built, featuring 4 thermoforming lines and 1 lamination line. This facility, located at Navigator’s Aveiro industrial site, is integrated with the pulp mill on-site and began commercial production in October 2024. The project is progressing with a focus on developing new products and advanced barrier solutions, aimed at improving both functional performance and environmental sustainability.

It emerged in the aftermath of the COVID-19 lockdown period, driven by the environmental urgency to find sustainable alternatives to single-use plastic, leveraging the unique qualities of virgin Eucalyptus globulus fibre and Navigator’s R&D and industrial capabilities.

Potential future developments

Looking ahead, the accumulated impact by 2030 is projected to reach 204 jobs and a total of 42,570 tonnes of CO₂ emissions avoided. By then, the investment in production infrastructure will have reached €97 million. From 2030 onwards, the project is expected to reduce CO₂ emissions by over 13,800 tonnes annually, with its carbon footprint being approximately 1,190 kg CO₂ emissions/tonne lower than conventional polypropylene.

This growth will be mostly driven by value added, home compostable solutions aimed at replacing single-use applications such as coffee capsules and single-portion packs, which pose significant recycling challenges and are expected to face major hurdles in complying with PPWR.

The sustainable growth of this project – and of similar initiatives across Europe – will depend heavily on the ability of the European innovation ecosystem to remain technologically ahead of Asian competitors, who benefit from low production costs reinforced by dumping practices. At the same time, the productivity of pulp thermoforming technology must gradually approach the levels achieved by plastic thermoforming and injection, closing the existing cost gap.

Current contribution

This project delivers high impact across environmental, economic and social dimensions. So far, it has created 40 jobs and replaced 200+ tonnes of fossil-based plastic packaging, thereby avoiding 238+ tonnes of CO₂ emissions. Unlike plastic packaging, which is often non-recyclable and can only be recovered through energy valorisation, virgin moulded cellulose is fully recyclable and/or compostable. On the other hand, it replaces the import of sugarcane bagasse products from Asia, which raise concerns regarding food safety, are produced using a high percentage of coal-based energy and whose transport to Europe emits about 1.35 tonnes of CO₂ per container.

On the R&D front, this project has been advancing applied research focused on developing Eucalyptus globulus fibre furnish and barrier property solutions. It has also been strengthening collaboration between Navigator’s research institute, universities, chemical and technology companies, and clients across Europe, while actively incorporating insights from overseas partners.

It’s the 1^st industrial initiative worldwide to use Eucalyptus globulus fibre with thermoforming technology, which has relied on long fibre species, sugarcane bagasse and recycled fibre (unsuitable for food contact). Eucalyptus globulus stands out as the silvicultural species with the highest levels of forest productivity, recyclability and industrial efficiency in Europe, making it an outstanding renewable raw material for mass consumption applications.