AIMPLAS Working to Develop Valuable Packaging Applications From Fish-Processing Waste

AIMPLAS, a Valencia, Spain-based research and technology center, is participating in a European project designed to develop an eco-friendly barrier coating for food packaging from fish gelatin as well as cosmetics packaging from waste fishing nets. 

Dubbed EcoeFISHent, the broader project involves 34 partners from seven countries and has a budget of 18.5 million euros. It launched in October 2021 and is due to wrap up in September 2026. The effort has received funding from the European Union’s Horizon 2020 research and innovation program.

Dr. Lodovico Agostinis is leading the project for AIMPLAS, which has been active in the plastics industry for more than 30 years. Andrea Morandini and Lola Gomez work with him in AIMPLAS’ Synthesis and Packaging Groups. AIMPLAS boasts 240 employees, 840 member companies, some 3,300 customers and annual sales of 21.3 million euros.

This latest effort aims to streamline the fishing industry’s operational flow, including its industrial side-streams. The group is exploring how to develop products from these materials for use in various products, including fertilizers, biodiesel, components for cosmetic applications, polymer-based automotive constituents, and packaging for cosmetic products.

“The EcoeFISHent project is almost at the end of the Optimization & Integration Phase and it is approaching the Scale-Up & Validation Phase,” Agostinis said in a mid-July email interview.

This group so far has validated many extraction protocols, such as the one for gelatin and bioactives production, as well as the design of pilot plants being installed by its industrial partners. At the same time, AIMPLAS is launching evaluations of the optimized methodologies and processes in terms of economic, environmental and social impacts.

He said the group will install EcoeFISHent pre-processing pilot units (EPPU) –– one in the AsdoMar tuna processing plant in Olbia, Italy, and another in the harbor of Genoa, Italy, which will be operated by the local public utility that manages waste there. The pilot units are due to be operating by the end of September.

Agostinis explained that the extraction of fish gelatin involves cleaning and pre-treating fish skins, bones, and other collagen-rich parts to remove non-collagenous proteins, fats, and minerals. These parts are treated and heated in water to extract the gelatin, which is then filtered to remove any remaining solids and impurities and finally dried. Fish gelatin is a sustainable and readily available resource as a byproduct of the fish processing industry.

Fish gelatin is particularly suitable for applications where its biodegradability and edibility are advantageous. That’s why AIMPLAS and EcoeFISHent project partners such as SAES Coated Films SpA and the Proplast technology center are focusing on edible films or coatings for sustainable flexible packaging solutions as possible end uses. He cited examples of sustainable films as those made from polylactic acid (PLA) or from Mater-bi, a family of biodegradable and compostable bioplastics from starch by Novamont SpA.

AIMPLAS believes fish gelatin eventually can be used as a coating on polyolefin packaging, including both polyethylene (PE) and polypropylene (PP) but notes the need to address certain considerations for that to work. Those types of films may require surface treating to ensure strong adhesion between the gelatin coating and the polyolefin substrate.

Also, while gelatin provides good oxygen and carbon dioxide barrier properties, its moisture barrier properties are not as strong, Agostinis said, which might limit its application for certain food products.

When considering gelatin coatings on materials such as PE or PP, a key challenge involves maintaining recyclability. To do so, it's crucial that the gelatin coating does not compromise the recycling process of the base material. This requires careful formulation and testing to ensure compatibility with recycling streams.

In summary, Agostinis said, gelatin-coated packaging presents a versatile solution that can be tailored to be recyclable, compostable, or even both, depending on the application and design choices. By leveraging gelatin's biodegradable properties and optimizing its use with various base materials, AIMPLAS hopes to help manufacturers meet the growing demand for sustainable packaging solutions that minimize environmental impact.

Another aspect of this project, meanwhile, involves recovering and repurposing used fishing nets, including those made from polyamide (nylon) and polyethylene. This involves sourcing them from various channels such as fishing communities, ports, marine clean-up initiatives, and specialized recycling programs. The group collects the nets in question after they have been discarded or damaged beyond repair.

AIMPLAS and Proplast are in charge of this aspect of the EcoeFISHent project. Polyethylene nets, studied by AIMPLAS, are known for their toughness and chemical resistance. Polyamide nets, the focus of PROPLAST, are valued for their durability and strength, making them common in fishing gear. Both types currently are recycled by melting the plastic to create items such as containers, pipes, and more fishing gear.

One of the project’s targets involves developing skin-care products formulated with intermediates such as omega-3 and collagen derived from marine sources. So, Agostinis said, “it is natural to synergize this development with upcycling processes for fishing nets. This natural synergy motivated AIMPLAS and Proplast to prioritize sustainable solutions for cosmetic packaging, starting with utilizing other marine by-products like discarded fishing nets.”

Such nets are a significant issue when it comes to health of the ocean. The Food and Agriculture Organization estimates that at least 640,000 tonnes of fishing gear (also known as ghost gear) are lost or abandoned in the ocean every year, which negatively impacts fish stocks and the entire ecosystem.

WWF Italy, in association with the Marine Protected Area of Portofino, are working to map and remove the ghost gear, when feasible, in collaboration with a scuba diving association. This collected nylon and PE waste is then reused as secondary raw materials.

Efficient logistics and collection are crucial to maximizing recovery rates of ghost nets and minimizing environmental impact. Agostinis notes that recycling technologies must be capable of handling both polyamide and polyethylene nets effectively, ensuring they can be transformed into usable products without compromising their properties and quality.

When considering the potential types of packaging they might create from these materials, AIMPLAS and Proplast say they are approaching the project with an open mind to explore various options. This includes evaluating the possible use of recycled PE and nylon nets in the production of rigid jars, tubes, flexible pouches, and other formats that could be suitable for cosmetic applications.

“The decision-making process,” said Agostinis, “will be guided by practical considerations such as the viscosity characteristics (melt flow index) of recycled materials and their compatibility with the specific cosmetic formulations developed by EcoeFISHent project partners.”

While its efforts are currently focused on Europe, AIMPLAS is keen to expand its market opportunities and collaborations to the U.S. and Latin American markets.

“As a technological center,” it says, “we are open to new opportunities as well as knowledge transfer to other companies and packaging sector actors that might be interested in our know-how.”