CORAL:Compostable Foams from Renewable Algae Sources: development and identification of strategies for their implementation
Lead Research Organisation:
Brunel University London
Department Name: Chemical Engineering
Abstract
A system that reduces the impact of plastic packaging waste by keeping materials in the economy is urgently needed. Around 47 Mt
of plastic packaging waste leaked from collection systems and polluted our environment in 2019. This figure is continuously
increasing worldwide due to the booming of new lifestyles, such as express delivery services. Therefore, coordinated action between
the entire plastics value chain is required to redesign the plastic systems, from capital investment for research in bioplastics
development to international cohesion in waste management standardisation or implementation of measures to increase consumer
awareness. CORAL aims to develop a family of upscalable algae-based and compostable foams as a sustainable alternative for
packaging foams for delivery (e.g., expanded polystyrene, polyethylene and polyurethane) and to investigate their applicability and
acceptability within the waste management system to identify strategies for their successful implementation. CORAL uses algae-based feedstocks as an alternative to other biobased material sources that compete with food production to manufacture foams by
combining mechanical foaming and sol-gel transition of the biopolymer blend. In addition, this project uses an eco-design approach
for formulation and processing development, considering the environmental impact of the foams by integrating Life Cycle Analysis
(LCA) during the development stage and compliance with home-composting certification schemes. CORAL acknowledges that
sustainable materials research is only a small niche for a circular economy. Thus, the project explores the attitudes toward CORAL's
foams, along with bioplastics in general, from a broad stakeholders' perspective to understand the challenges associated with their
implementation and end-of-life to influence the development of coherent policy and effective waste management systems
of plastic packaging waste leaked from collection systems and polluted our environment in 2019. This figure is continuously
increasing worldwide due to the booming of new lifestyles, such as express delivery services. Therefore, coordinated action between
the entire plastics value chain is required to redesign the plastic systems, from capital investment for research in bioplastics
development to international cohesion in waste management standardisation or implementation of measures to increase consumer
awareness. CORAL aims to develop a family of upscalable algae-based and compostable foams as a sustainable alternative for
packaging foams for delivery (e.g., expanded polystyrene, polyethylene and polyurethane) and to investigate their applicability and
acceptability within the waste management system to identify strategies for their successful implementation. CORAL uses algae-based feedstocks as an alternative to other biobased material sources that compete with food production to manufacture foams by
combining mechanical foaming and sol-gel transition of the biopolymer blend. In addition, this project uses an eco-design approach
for formulation and processing development, considering the environmental impact of the foams by integrating Life Cycle Analysis
(LCA) during the development stage and compliance with home-composting certification schemes. CORAL acknowledges that
sustainable materials research is only a small niche for a circular economy. Thus, the project explores the attitudes toward CORAL's
foams, along with bioplastics in general, from a broad stakeholders' perspective to understand the challenges associated with their
implementation and end-of-life to influence the development of coherent policy and effective waste management systems
Publications
Torrejon V
(2025)
Transforming seaweed into bioplastics: a review of cultivation, harvesting and processing methods
in Applied Phycology
| Description | This project has made significant progress toward the development of seaweed-based biomaterials. While the research is ongoing, key achievements include: • WP1. Preparation and characterisation of hydrogels. - Progress in the development of hydrogels from raw seaweed biomass and carrageenan-based formulations, with rheological properties. - A review paper titled "Transforming seaweed into bioplastics: a review of cultivation, harvesting and processing methods' was successfully published, providing an overview of the state-of-the-art in seaweed bioplastics. - Manuscript preparation for D1.1 ('Production and Characterisation of Biobased Hydrogels from Raw Algae-Based Sources') is underway, with submission expected within the next three months. • WP2. Formulation and process development of Coral Foams. - Significant experimental work has been conducted on foam formulation, focusing on optimising viscosity and maximising formulation solid content. - Challenges in achieving suitable viscosity for stable foam structures have led to a parallel strategy to address these issues: (1) Freeze-drying (lyophilisation) approach, shifting potential applications to premium packaging and biomedical uses, (2) Internal funding application at Brunel University for the purchase of an industrial foamer to enable foaming at higher viscosities, (3) Exploration of external collaborations to gain access to industrial foamers. - These adjustments ensure that the project remains aligned with its objectives while also broadening its scope of applications. • WP3. Environmental Impact Assessment. - Access to SimaPro and Ecoinvent has been secured and initial Life Cycle Assessment (LCA) training has commenced to evaluate the environmental footprint of the materials. • WP4. Stakeholder Attitudes and Policy Development. - Collaboration has been established with two researchers specialising in packaging technology, stakeholder engagement and qualitative research, ensuring a solid foundation for WP4. - This WP is now fully operational. • WP 5. Dissemination and Communication - The official project website has been completed and launched, providing a platform for disseminating research progress and engaging with stakeholders. - An abstract has been accepted for a poster and oral presentation at the 33rd European Biomass Conference and Exhibition in Valencia (Spain) for the 9th of June 2025. It highlights research on sargassum-based hydrogels and films as potential bioplastic materials. • WP7. Training and Knowledge Transfer. - Completion of two professional development courses (1) UCL course in policy engagement, (2) Data Ethics, AI and responsible Innovation by the University of Edinburgh. - Ongoing collaboration with Professor Jurgita Malinauskaite for a peer-reviewed paper on policy frameworks or seaweed-based bioplastics. - The development of a MOOC on bioplastics formulation and development is in progress These achievements demonstrate substantial progress toward the project's overall objectives, contributing to scientific knowledge, industry engagement and policy development. |
| Exploitation Route | The findings from this project will have implications across academia, industry and policy. • Academia impact - The project will contribute to peer-reviewed publications, contributing to scientific knowledge on seaweed-based bioplastics. - Research insights will support future grant applications to scale up bioplastics production and expand industrial collaborations. • Industrial applications - Results from WP1, WP2 and WP3 will inform bioplastic manufacturers and packaging developers about the feasibility of seaweed-based foams. - Industrial collaborations, such as those with The Seaweed People will facilitate the potential commercialisation of packaging solutions. • Policy influence - The LCA and qualitative research in WP3 and WP4 will help policymakers and waste management organisations evaluate the practical implementation of compostable packaging solutions. - Ongoing collaboration with Professor Jurgita Malinauskaite will produce policy recommendations, supporting regulatory frameworks for seaweed-based bioplastic innovation. • Public Engagement and consumer awareness - The CORAL Project website will serve as an educational resource on bioplastics. - Upcoming conference presentations will disseminate findings and will foster future collaborations. - The MOOC will offer an accessible learning opportunity on bioplastics, reaching a wider audience once the platform challenge is resolved. |
| Sectors | Agriculture Food and Drink Manufacturing including Industrial Biotechology Retail |
| URL | http://www.coralbioplastics.com |
| Description | While some findings are still emerging, the project has already begun influencing industry collaborations, policy discussions and public awareness on seaweed-based materials 1. Economic and societal impact • Industry engagement and commercial potential (emerging and evolving) - The project has established key collaborations with industry partners, who are supplying raw materials and exploring the potential scalabiliy of seaweed-based bioplastics. - Through ongoing technical development in WP2, the project is working towards scalable, cost-effective foam processing with potential applications in packaging, biomedical materials and high-performance insulation. - This research aligns with growing industry demand for compostable materials. • Policy and regulatory impact (long-term potential) - Initial findings will inform policy discussions around compostable materials and the use of seaweed resources as feedstocks for bioplastics development (WP4) - Collaboration with Professor Jurgita Malinauskaite will contribute to a peer-reviewed paper on regulatory frameworks impacting the development of seaweed-based bioplastics. • Public engagement and behavioural change - The project website is serving as a platform making information about bioplastics and sustainable materials accessible to a broad audience. - Participation in the 33rd European Biomass Conference and Exhibition will disseminate findings. - The MOOC development is a key initiative to increase knowledge accessibility. 2. Challenges overcome to achieve impact • Technical barriers in material development - The high viscosity of foam precursors has required adaptation of processing methods, including the exploration of lyophilisation as an alternative foaming approach - Lack of access to industrial foaming equipment has led to applying for internal funding to purchase equipment and seeking external collaborators with relevant facilities. • Barriers to MOOC development - While course content is being developed, the learning platform uncertainty has created a bottleneck. We are actively working on alternatives. 3. Academic impact and new research directions • Interdisciplinary and collaborative approach - The project integrates phycology, material science and qualitative research. - Research collaborations with Kingston University and different researchers from different institutions have expanded in further material characterisation and stakeholder research, strengthening cross-disciplinary knowledge transfer. - The networking day at Brunel university (August 2024) for Marie Curie Postdoctoral Fellows and Doctoral researchers successfully impacted the fellow network and identify future opportunities and collaborations. • Contributing to the Global Sustainability Agenda - The project aligns with US Sustainable Development Goals - By addressing misconceptions and regulatory challenges, the findings will contribute to broader adoptions and acceptance of seaweed-based materials. 4. Summary and Future Impact CORAL is starting to make impact in industry engagement, policy influence, materials development and public education on sustainable materials. While challenges remain in technical and MOOC development, the project is actively mitigating these barriers through strategic collaborations, funding applications and alternative process development. Future impact is expected to materialise through: - Peer-reviewed publications - Industry partnerships - Regulatory insights |
| First Year Of Impact | 2025 |
| Sector | Agriculture, Food and Drink,Manufacturing, including Industrial Biotechology,Retail |
| Impact Types | Societal Economic Policy & public services |
| Description | Early Career Research Travel Award |
| Amount | £800 (GBP) |
| Organisation | Brunel University London |
| Sector | Academic/University |
| Country | United Kingdom |
| Start | 02/2025 |
| End | 02/2025 |
| Description | Research Culture Seed Fund |
| Amount | £2,500 (GBP) |
| Organisation | Brunel University London |
| Sector | Academic/University |
| Country | United Kingdom |
| Start | 06/2024 |
| End | 08/2024 |
| Description | Santander Universities Research Awards 2024 |
| Amount | £1,000 (GBP) |
| Organisation | Santander Bank |
| Sector | Private |
| Country | United States |
| Start | 07/2024 |
| End | 12/2024 |
| Description | Co-organisation of Early Career Researchers Summer Day for the Marie Curie Alumni Association (MCAA) at Brunel University London |
| Organisation | Brunel University London |
| Country | United Kingdom |
| Sector | Academic/University |
| PI Contribution | As the co-organiser of the event, along with the chair of the UK Chapter MCAA, Quentin Loisel, I contributed to this collaboration by: - Conceptualising and leading the networking day at Brunel University - Organising workshops and networking sessions |
| Collaborator Contribution | - The MCAA contributed with £2500 for the organisation of the event - Brunel University London contributed with additional £2500 |
| Impact | - Brought together over sixty current Marie Curie Fellows and Doctoral Students within the UK |
| Start Year | 2024 |
| Description | Material characterisation and Knowledge Transfer at Kingston University |
| Organisation | Kingston University London |
| Country | United Kingdom |
| Sector | Academic/University |
| PI Contribution | - Knowledge transfer. Sharing expertise on bioplastic formulation and processing insights with Dr Heba Ghazal. - Collaborative research. Initiating joint research efforts to investigate the properties of hydrogels using texture analysis and analysis techniques (LC-ICP-MS), which were not available at my home institution. - Funding prospects. Identifying and contributing towards future joint funding proposals, particularly in areas related to sustainable plastic packaging and pharmaceutical packaging. - Publication opportunities. Working towards joint publications based on proof-of-concept data generated during the visit. |
| Collaborator Contribution | The faculty and research team at Kingston University have significantly contributed to this collaboration by providing specialised research infrastructure and technical expertise for the characterisation of my hydrogels and raw materials. Key contributions include: - Access to specialised equipment. Granding access to a texture analyser (for gel strength measurements) and LC Coupled with Inductively Coupled Plasma MS (LC-ICP-MS) (for elemental composition analysis), which are essential for my project, but unavailable at my home institutions. - Technical support and training. Offering guidance on characterisation and data analysis, ensuring high-quality and reproducible results. - Interdisciplinary collaboration. Facilitating engagement with faculty researchers in pharmacy and environmental science, which enhances the interdisciplinary scope of the study. |
| Impact | - Research and data generation. (1) Collection of data on the mechanical properties of seaweed-based hydrogels using texture analysis (2) generation of elemental composition data of raw materials using LC-ICP-MS. - Academic Publications (In Progress). This research collaboration is expected to lead to one joint publication (D1.1). |
| Start Year | 2024 |
| Description | Material characterisation and Knowledge Transfer at Kingston University |
| Organisation | Kingston University London |
| Country | United Kingdom |
| Sector | Academic/University |
| PI Contribution | - Knowledge transfer. Sharing expertise on bioplastic formulation and processing insights with Dr Heba Ghazal. - Collaborative research. Initiating joint research efforts to investigate the properties of hydrogels using texture analysis and analysis techniques (LC-ICP-MS), which were not available at my home institution. - Funding prospects. Identifying and contributing towards future joint funding proposals, particularly in areas related to sustainable plastic packaging and pharmaceutical packaging. - Publication opportunities. Working towards joint publications based on proof-of-concept data generated during the visit. |
| Collaborator Contribution | The faculty and research team at Kingston University have significantly contributed to this collaboration by providing specialised research infrastructure and technical expertise for the characterisation of my hydrogels and raw materials. Key contributions include: - Access to specialised equipment. Granding access to a texture analyser (for gel strength measurements) and LC Coupled with Inductively Coupled Plasma MS (LC-ICP-MS) (for elemental composition analysis), which are essential for my project, but unavailable at my home institutions. - Technical support and training. Offering guidance on characterisation and data analysis, ensuring high-quality and reproducible results. - Interdisciplinary collaboration. Facilitating engagement with faculty researchers in pharmacy and environmental science, which enhances the interdisciplinary scope of the study. |
| Impact | - Research and data generation. (1) Collection of data on the mechanical properties of seaweed-based hydrogels using texture analysis (2) generation of elemental composition data of raw materials using LC-ICP-MS. - Academic Publications (In Progress). This research collaboration is expected to lead to one joint publication (D1.1). |
| Start Year | 2024 |