From Brewery Waste to Bio-based Circular Packaging

 The EU-funded BioSupPack project has demonstrated that brewery waste can be transformed into high-performance bioplastics for sustainable packaging. Over five years, the 18-member consortium developed and validated polyhydroxyalkanoate (PHA and PHB) materials and production processes that offer viable alternatives to fossil-based plastics while supporting compliance with the EU Packaging and Packaging Waste Regulation (PPWR).

Six innovation results

At a demonstrative scale and in real operational environments, BioSupPack developed and validated key innovations that address critical challenges in the packaging industry:

1.     Biorefinery Process for PHB Production from Brewery Spent Grains: BioSupPack has developed a scalable bioprocess that efficiently converts brewery spent grains into high-purity PHB through an innovative plasma pretreatment and microbial fermentation. This innovation transforms a low-value waste stream into a functional biopolymer while creating industrial symbiosis between breweries and bioplastics producers. The process has reached TRL 6, demonstrating feasibility in industrially relevant environments.

2.    PHA-Based Coating Formulations and compostable Fibre-based Packaging: BioSupPack has developed PHA plastisol coatings that are 99% biobased and fully biodegradable. These coatings can be applied to paperboard as alternatives to PE coatings, as well as to textiles as replacements for PVC. The innovation is protected by Centexbel’s patent and has reached TRL 6, ready for licensing to coating manufacturers.

3.    Compostable Fibre-Based Packaging: The consortium has created industrially compostable, fibre-based packaging with barrier properties comparable to fossil-based plastics. Applications include ice cream cups and trays. This solution enables companies to meet sustainability goals while offering dual end-of-life options. The innovation has reached TRL 7.

4.    PHB-Based Formulations for Rigid Packaging: Sabiomaterials has developed PHB-based materials optimized for rigid packaging applications such as bottles and displays for retail applications. The materials are produced from renewable waste streams, are fully biodegradable, both mechanically and enzymatically recyclable, and have been specifically formulated for improved processability by extrusion blow moulding and injection moulding. The innovation has reached TRL 7, with industrial-scale production.

5.    Rigid packaging for different sectors: ILAB has obtained bottles for dressings and personal care products and Aimplas has developed and produced a beer bottle display for the retail sector.

6.    Sorting prototype for the novel biobased and enzymatic recycling process: The sorting prototype for the packaging waste from IRIS, will allow the recovery of the new packaging waste streams for the subsequent enzymatic recycling, which has shown to be an effective end-of-life for these packaging materials, due to the development of novel selective enzymes.

From brewery waste to bio-based plastic packaging. IMAFGE: AIMPLAS

Market relevance and industrial impact

BioSupPack’s innovations directly address the packaging industry’s transformation driven by the EU Packaging and Packaging Waste Regulation (PPWR). With the requirement that all packaging must be recyclable by 2030, and growing demands for sustainability from consumers and regulators, the project’s results provide validated pathways for industry to transition from fossil-based to biobased, circular packaging solutions. The technologies developed can be integrated into existing manufacturing infrastructure, reducing technical and economic barriers to adoption.