Circular economy in packaging

Company and project background

Can you give us a brief overview of your business and the specific project you implemented?

Alchim di Masante & C. S.a.s. is an accredited analytical laboratory offering chemical, physical, microbiological, and environmental testing services. Its core activities include water and air quality analysis, food safety testing, waste and compost evaluation, and material characterization (thermal, mechanical, and structural). The lab supports companies and public bodies with customized, regulation-compliant analyses aimed at ensuring product quality, environmental compliance, and industrial innovation.
Moreover, it provides companies with products and services regarding food analytic analysis, and the development of ad-hoc innovative products to cover companies’ needs.
Alchim di Masante & C. S.a.s. specializes in innovation for the agri-food and packaging sectors, particularly in analytical testing and product development. In the Eggshellent project, we developed an eco-friendly egg packaging prototype composed of micronized eggshell powder and recycled cellulose pulp.

What motivated you to make your business more circular?

The project was driven by the need to reduce raw material consumption, particularly cellulose, and the observation that eggshell waste is massively underutilized. In Italy alone, industrial egg processing generates over 25,000 tonnes/year of shells, typically composted without maximizing their material value.
Moreover, the initiative originated from a clear need expressed by a local egg producer, who was seeking a sustainable, circular solution to manage the large volumes of shells generated during processing.
In addition, growing customer demand for sustainable packaging, combined with EU regulations phasing out single-use plastics, motivated us to pursue circular solutions that are both technically feasible and environmentally impactful.

Implementation process

What were the main objectives of your feasibility study?

The main goal of our feasibility study was to create and validate a new type of egg packaging that’s both recyclable and compostable—using materials that would otherwise go to waste. We set out to find the right balance: the optimal particle size and percentage of eggshells to include, while still maintaining the strength and durability needed for safe transport.
At the same time, we wanted to understand just how much CO₂ we could save by replacing a portion of virgin cellulose with this circular alternative.
Indicators set included:

• ≥20% cellulose reduction
• ≥20% CO₂eq emissions reduction
• ≥40% eggshell waste diverted from low-value disposal routes

What activities did you carry out during your project?

We started by sourcing eggshells and processing them through micronization to obtain a fine, consistent powder. In the lab, we carried out formulation trials, testing different concentrations of eggshell powder to identify the most effective mix.

Next, we designed and produced custom gypsum molds to create prototype trays, which were then tested for compression strength, tear resistance, recyclability, and microbiological safety, ensuring compliance with food-contact standards.
Alongside the technical work, we conducted a market analysis to assess interest and gather feedback.
To protect our innovation, we performed a prior art search and proceeded to file a patent application for the material and process.
The project involved close collaboration between our in-house R&D team, external microbiology and materials laboratories, and technical consultants, ensuring scientific rigour and industrial relevance at every stage.

 What feedback did you receive from stakeholders (customers, suppliers etc.)?

Egg producers, packaging manufacturers, and retailers showed strong interest in the solution. They highlighted the brand value of using waste-based materials and appreciated the mechanical properties and compliance with food safety standards.

Their feedback led us to:

• prioritize smaller eggshell particle sizes (<100 µm)
• improve mold design for better structural outcomes
• begin preparing for scaling with industrial partners

Impact & Outcomes

What were the main results and outcomes of the project for your company?

One of the key outcomes of the project was the development of a validated prototype of molded egg packaging made entirely from waste materials—specifically, eggshell powder and recycled cellulose.
This prototype demonstrated a compression strength, outperforming standard commercial trays. This confirmed the material’s structural reliability and suitability for real-world use.
We also verified that the packaging is both recyclable and compostable, making it fully compatible with circular waste management systems.
To safeguard the innovation, we filed a patent covering both the composite formulation and the manufacturing process.

Did you detect a positive impact of circular transition for your company and for the environment?

Yes. We observed several estimated environmental benefits, based on preliminary calculations and scaling scenarios:
– 20% reduction in virgin cellulose use per tray
– Estimated 20% CO₂eq emissions reduction compared to conventional pulp packaging

If scaled, the potential to save up to 10,800 tonnes of cellulose per year, 43% of eggshell waste from our partner supply chains could be diverted from composting and redirected into packaging production.
While these figures are based on lab-scale data and projected material flows, they provide a strong indication of the environmental value of the solution. This has helped us improve our sustainability profile and explore new market opportunities.

Have you already implemented any changes?

While the biocomposite material is not yet in full-scale production, it has been fully integrated into our product development pipeline. Building on the positive results of the feasibility study, we aim to:

• assess machinery adaptation requirements to transition from lab-scale to industrial production;
• organize pilot trials with packaging manufacturers to validate the material on pre-industrial lines;
• prepare technical documentation necessary for certifications, including compostability, recyclability, and MOCA compliance for food contact

Lessons learned

What key lessons did you learn regarding circular innovation?

One of the key lessons we learned on our journey with circular innovation is the importance of starting with locally available and consistent waste streams. It may sound obvious, but this foundation is absolutely critical. It ensures supply chain stability, simplifies logistics, and supports the overall sustainability of the solution from the outset.

Another important insight is the value of early laboratory testing and a solid intellectual property (IP) strategy. These two elements might not seem urgent at the beginning, but they add significant long-term value. Testing early helps avoid costly surprises down the line, and securing IP gives you the freedom to grow and protect your innovation in a competitive landscape.

Equally, we found that market feedback must be integrated early and often. It’s not enough to have a great material or technology — if it doesn’t respond to real industry needs or user expectations, it risks becoming irrelevant. Feedback helped us steer our R&D in the right direction, making sure we were building something truly valuable.

And if I may share a pleasant surprise: we were genuinely impressed by the technical performance of waste-derived materials. There’s often a bias — sometimes even skepticism — around using waste as a resource. But in our case, the results have shown that with the right processes, waste-based biocomposites can meet, and sometimes exceed, the performance of conventional materials.

Did you encounter any challenges?

Yes — like any truly innovative project, our journey came with its fair share of challenges.

One of the first major hurdles we faced was ensuring consistency in eggshell quality and micronization. While eggshells might seem like a simple waste material, their properties can vary significantly depending on the source. Achieving the right particle size and purity was crucial to ensure a stable and high-performing biocomposite.

Another key limitation was working with small-scale molding equipment. Lab-scale tools are incredibly useful for experimentation, but they don’t always reflect the conditions and constraints of industrial production. This gap made it harder to predict how our material would behave on a larger scale — which brings me to another challenge.

We encountered difficulty in getting in contact with egg packaging producers, especially because most of them are not based in Italy. Establishing these industry connections took time and persistence. Without strong local partners, it’s more complicated to set up pilot tests or receive direct technical feedback — both of which are crucial at this stage of development.

On top of that, we’ve had to navigate a complex certification landscape. New materials, especially those intended for food contact, must meet strict standards — including compostability, recyclability, and MOCA compliance. Preparing the technical documentation and aligning our product with these requirements has been demanding, but it’s essential for market entry and long-term credibility.

While some of these barriers are still ongoing, we’ve made significant progress by combining persistence, targeted R&D, and by seeking out international partnerships. It’s not always easy — but innovation never is. And every step forward brings us closer to making circular, waste-derived packaging a real, scalable alternative.

If you could do your project again, what would you do differently?

If we could do the project again, there are definitely a few things we would approach differently.

First, we would engage with industrial-scale partners much earlier. Their input is invaluable, especially when it comes to scaling and validating the process. Starting those conversations sooner would have saved us time and helped us anticipate technical constraints.

Second, we would map out the regulatory and certification requirements right from the start. Understanding what’s needed for food contact compliance, compostability, and recyclability early on helps shape both the material design and the R&D path.

Lastly, we’d allocate more time to refining the drying and forming processes. These steps turned out to be more complex than expected, and we learned the hard way that even small inefficiencies can become major obstacles at scale.

Future plans & recommendations

What are your next steps towards circular transition?

As our next step in the circular transition, we’re preparing to move into pilot-scale production in collaboration with industrial partners. This will allow us to validate our biocomposite material under real manufacturing conditions and prepare for market entry.
We’re also working to expand the applications of our material beyond egg cartons — into other molded fiber formats like trays and clamshells, which share similar technical requirements.
In parallel, we’re exploring strategic partnerships for logistics and distribution to ensure our solution can scale efficiently and sustainably. Collaboration is key to pushing circular innovation beyond the lab.

Is there any advice you would give to other SMEs looking to adopt a circular business model?

For other SMEs looking to adopt a circular business model, our advice is to start with waste streams you can access and control. It may seem simple, but having a stable, local input source is fundamental.
Also, always prioritize both functionality and sustainability — it’s not enough for a product to be green; it has to work well in its intended context.
Don’t postpone IP protection — securing your innovation early gives you leverage and confidence to grow. And finally, validate as early as possible through testing in real-life conditions and continuous dialogue with industry. Waiting too long can slow progress or lead you down the wrong path.

How can policymakers or financial institutions better support businesses in adopting circular practices?

To better support circular innovation, grants for pilot production and certifications would make a big difference — especially for early-stage startups and SMEs. These are essential but costly steps that often create bottlenecks.
Policymakers could also facilitate waste valorization networks, helping connect waste producers with innovators who can transform that waste into new resources.
In addition, offering training and mentoring in circular design and life-cycle assessment (LCA) would empower more businesses to make the shift confidently.
Frankly, more accessible funding for small-scale circular prototyping would have significantly accelerated our process. Supporting the early stages is where real impact starts.

Do you have any additional comments or reflections about your participation in the Up2Circ project?

Participating in the Up2Circ project has been a turning point for us. It gave us the opportunity to validate an idea that had strong potential, but needed structure, guidance, and resources to truly move forward.
Thanks to the program, we now have a protected innovation, a functional prototype, and most importantly, a clear path toward industrialization.
This experience not only accelerated our progress but also ensured that our efforts are fully aligned with EU sustainability goals.

We’re proud to have been part of this journey, and we’re excited to keep building toward a more circular future.