Background
As part of its PepsiCo Positive (pep+) sustainability agenda, PepsiCo is committed to reducing virgin plastic use and increasing the recyclability and compostability of its packaging. The beverage sector, in particular, presents unique challenges where durable, functional packaging must also align with environmental goals.
Fiber-based packaging is a promising alternative to conventional fossil-based plastics, but requires effective barrier coatings to ensure product protection. For beverage bottles, sprayapplied interior coatings must deliver high barrier performance while preserving recyclability through repulping with a fiber yield greater than 85%. Current coating technologies have demonstrated limitations in meeting these combined performance and sustainability targets, prompting the need to explore biodegradable polymer resins such as PHA and similar materials. PepsiCo seeks solutions that will enable the development of fully recyclable fiber-based beverage packaging using biodegradable polymer resins, ultimately contributing to its vision of a more circular packaging economy.
Challenge
We are looking for biodegradable polymer coatings or biodegradable resins that can be spray-applied to fiber-based beverage packaging (350 mL to 1 L in volume), deliver effective barrier performance, and enable high fiber recovery to support recyclability.
Solutions of interest include:
- PHA-based sprayable barrier coatings
- Biodegradable nanocomposite coatings
- Biodegradable resin systems
- Sprayable aliphatic polyester coatings, such as polybutylene succinate (PBS) and polybutylene adipate terephthalate (PBAT) blends
- Biopolymer crosslinked networks
Our must-have requirements are:
- Compatible with spray coating via standard nozzle sizes
- WVTR ≤ 0.31 g/m²/day at 23°C/50% RH; water loss < 1% over 6 months
- OTR ≤ 2.0 cc/ m²/day at 23°C/50% RH
- Derived from renewable resources and considered biodegradable
- Meets repulpability and fiber yield recycling requirements per the Voluntary Standard for Repulping and Recycling of Corrugated and Paper-Based Packaging (FBA/AF&PA)
What's out of scope:
- Materials not derived from biodegradable polymer resins
- Materials containing components prohibited or flagged for food contact, or that are unlikely to meet regulatory food contact safety requirements
Acceptable technology readiness levels (TRL): 5-9
- 5 - Validated in relevant environment
- 6 - Demonstrated in relevant environment
- 7 - Regulatory approval
- 8 - Product in production
- 9 - Product in market
What's in it for you?
Sponsored Research
Funding is proposal-dependent typically ranges from $25,000 to $100,000. Preference will be given to an integrated team that has all of the capabilities needed to develop the model. PepsiCo is excited to partner with external researchers.
Co-development
Work directly with our team of scientists and engineers with deep experience in material science, packaging, and bringing new products to market at massive scale.