Low-Pressure Treatment Strengthens Biodegradable Packaging While Cutting Energy Use

markrenngont

Researchers at Virginia Tech have developed an energy-efficient method to significantly enhance the strength and durability of biodegradable packaging, potentially accelerating the shift away from plastic.

The collaborative research team from the College of Agriculture and Life Sciences and the College of Natural Resources and Environment discovered that applying low-pressure cycles to cellulose-based materials improves their performance for packaging use—without the high energy costs of traditional processing.

“Petroleum-based plastics have dominated packaging for decades,” said Haibo Huang, associate professor in the Department of Food Science and Technology. “But their environmental persistence has raised serious concerns. Biodegradable alternatives are emerging, yet they often fall short in performance compared to plastics.”

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The team’s new technique bolsters the mechanical strength, gas barrier properties, and transparency of cellulose films—three key characteristics needed for food and commercial packaging. Crucially, the process also avoids the chemical treatments that have previously limited the scalability and sustainability of plant-based materials.

“Cellulose is abundant and biodegradable, but until now, it hasn’t been structurally robust enough for broad industrial use,” said Young Kim, associate professor in the Department of Sustainable Biomaterials and co-principal investigator. “With this method, we’ve shown that cellulose films can meet the performance standards required for real-world packaging.”

Unlike conventional methods that rely on high pressure and intensive energy input, the Virginia Tech approach uses repeated low-pressure treatments to restructure the cellulose internally. The results were surprising—even outperforming high-pressure techniques while preserving the material’s integrity.

“We didn’t expect low-pressure cycles to be this effective,” Kim said. “The material became not only stronger but also retained its quality, making it much more practical for commercial packaging.”

The breakthrough has drawn the attention of industry partners, with potential for scale-up and integration into existing production lines. The researchers, including Professors Audrey Zink-Sharp and Maren Roman, are also exploring further applications, such as antimicrobial versions for food-safe packaging.

“Our process offers a low-cost, scalable way for companies to adopt sustainable packaging solutions without sacrificing quality,” Kim noted.

With mounting concern over plastic pollution and a growing demand for eco-friendly alternatives, this innovation marks a promising step toward making biodegradable packaging a mainstream solution.

“This is just the beginning,” Kim added. “We’re optimistic that with continued development, sustainable packaging can become the norm, not the exception.”