MelOx

Coated paper food bags / Source: Melodea

AsiaCelluloseCompostableFlexibleFood & BeverageLightweightMelOxMoisture BarrierOil ResistantOxygen Barrier PackagingRecyclableStrongTransparent

WHAT WE SAY:

Ironically, one of the biggest barriers to packaging recyclability is the synthetic barrier substances applied to them. As demand for sustainable packaging booms, and with so few alternatives to conventional plastic-based coatings on the market, the need for a non-toxic solution is imperative.

But that's about to change with MelOx, a ready-to-scale oxygen barrier coating developed by Melodea. The Israeli startup uses groundbreaking technology to transform cellulosic fibres from wood and paper byproducts into a versatile liquid formula. The plant-based coating can be applied to an endless list of packaging units and substrates using standard coating machines, making the transition practically fuss-free. With successful trials and the acquisition of a US production facility now complete, there's no reason to doubt that MelOx could be the saviour we've been waiting for.

MelOx

WHAT IS MELOX?

MelOx is a barrier coating which provides oxygen, oil, and grease resistance to flexible food and consumer goods packaging. The coating offers the Paper and packaging sectors a next-generation alternative to toxic, non-recyclable Aluminium and plastic-based coatings that maintains product freshness.
The coating is made using proprietary industrial technology developed by Melodea, which extracts cellulose nanocrystals (CNC) from industrial forest byproducts. The isolated fibres are then mixed with water, producing a transparent gel which is formulated into coating products.
MelOx is 100% bio-based and performs well in both typical and tropical conditions. It is biodegradable, compostable, silicone and plastic free, printable, and holds PTS certification validating its recyclability. The coating also meets FDA food contact requirements. Interestingly, it can be washed off its substrate with water, according to Melodea's CEO, meaning that the packaging material can then be easily recycled following disposal.
The oxygen barrier is ideal for the storage of dried items: foods such as coffee beans, grains, and chocolate, as well as non-food products like laundry powders.
The patented formula can be applied as a high-performance coating on a variety of packaging materials including paper and paperboard, and can be used on pouches, lids, and Moulded Fibre units. Conveniently, MelOx is a drop-in replacement for conventional, oil-based coatings and is compatible with slot-die, rod coater, curtain, and gravure coating machines.
The coating is ready for use without the need for dilution or modification. It's simply mixed before use to ensure homogeneity and fluidity. The company recommends applying two coats on paper.
MelOx has a six-month shelf life and is delivered to customers in drums or IBCs. Product guidelines recommend cool but frost-free storage conditions within a temperature range of 5-25 degrees celsius, and should be stored out of direct sunlight.
Successful trials have already been conducted to showcase the coating's feasibility and performance, with the company now scaling production to bring the product to market in 2023. Melodea has opened a new manufacturing plant in the US to serve North and South American markets.

KEY PROPERTIES:

Compostable
Flexible
Lightweight
Moisture Barrier
Oil Resistant
Oxygen Barrier
Recyclable
Strong
Transparent

INDUSTRY:

Food & Beverage
Packaging

AVAILABILITY:

Limited Orders

DIVE DEEPER:

Plastic-based coatings are not only harmful to the planet, but pose major risks to human health – especially because they're so prevalent in food and beverage containers, leaching chemicals into the items we consume. Mounting evidence suggests that plastic is contributing to infertility, hormone-related cancers, and neurodevelopment disorders. Therefore, it's no surprise that plastic pollution, which has historically been an environmental issue, is now being touted as a human rights concern.
Yet many packaging products require barrier properties in order to protect and preserve their contents, which is why plastic and aluminium foil-based barrier solutions are still in use despite their toxicity. Applying these coatings to packaging also makes them non-recyclable, despite many brand claims to the contrary.
MelOx is a plant-based alternative, derived from Cellulose, the most abundant organic polymer on Earth. It can be sourced from a number of raw materials including Wood pulp, paper waste, flax, and Cotton.
The global nanocellulose market is projected to almost triple in size over the next three years – growing to USD 963 million by 2026 – demonstrating the demand for and potential of sustainable solutions derived from the plant source.
CNC, which is extracted from cellulose using Melodea's proprietary technology, has a number of properties which makes it uniquely versatile. It is strong, lightweight, transparent, durable, abrasion resistant, and compatible with water-based systems. It can even enhance the adhesiveness, scratch resistance, tensile strength, and anti-reflection qualities of the substrates and substances combined with it.

CNC is extracted at Melodea's pilot plant in Arad, Israel. The company plans to acquire global plants by licensing its technology and striking commercial agreements with packaging suppliers in order to scale its bio-based solutions. It has a semi-industrial plant in Sweden, which is Europe's first CNC extraction facility, and acquired a plant in the US in October 2022.
The company claims that its production process recycles up to 95% of the chemicals used, adding to the company's environmental credentials.
Melodea states that its products are "being adapted by leading food and goods manufacturers" as part of its efforts to address global waste. According to the startup's CFO Zvika Weiss, the coating has already been piloted by major companies.
MelOx is not designed for liquid packaging, something that the company is looking to address in the long term. Melodea is also exploring CNC's wider potential: as well as being an enhancement additive for barrier coatings, it can also be processed to make composite foams, ultra thin coatings, and thick films. Future CNC-based applications could include conductive components for printed electronics as well as fibre and textile enhancement.
To date, Melodea has raised USD 20 million in capital from a global group of stakeholders and investors.

Paper packaging using Melodea's barrier coating / Source: Melodea

MelOx is made using forestry byproducts as feedstock / Source: Shutterstock

KEY FACTS:

$963mn

The global nanocellulose market is projected to be worth USD 963 million by 2026

95%

of the materials used in the CNC production process are recycled

$20mn

Melodea has raised USD 20 million in capital

Key Questions to Ask:

When will MelOx be commercially available?

With a new plant in the US, and commercial partners on board, Melodea has predicted that shipments to American customers will commence from April 2023. If you're based in another region, it might be worth contacting the company to explore your options. In the meantime, we'll be keeping a close eye on MelOx's availability and update you as details emerge.

What materials are you planning to use the coatings on?

Applying a recyclable and compostable coating on non-recyclable packaging is a futile endeavour. Melodea indicates that its coating can be applied to plastic and bioplastic packaging, and while this may be technically true, is it the best use of a plant-sourced coating? To maximise MelOx's potential, it's pretty obvious that the materials the coating is applied to must have sustainable end-of-life options too. The Fibre Bottle by Cullen is a great example, although MelOx would only be effective for dried goods like herbs and spices; Refibr takeaway food packaging could also work well with the coating. That said, having access to a non-toxic barrier coating to stop microplastics leaching into food items is progress nonetheless, at least until plastic packaging is completely designed out.

Can you explore Melodea's supply chain?

While the startup claims to use forestry byproducts, facilitated by strategic partnerships with two of the world's leading pulp and paper companies – Klabin S.A. and Holmen AB – how sustainable is the sourcing of the raw material that Melodea depends on? And what about the waste material that's left behind after the extraction process? Melodea's CEO has stated that CNCs are only a fraction of the plant fibres used, but doesn't indicate what happens to the rest of the feedstock. A transparent supply chain is fundamental to a business' sustainability profile, so you should do your due diligence. You could explore innovative ways to make use of the leftover feedstock in your product – turning it into moulded fibre packaging or paper for labels and banderoles – to minimise waste.

Is there potential to integrate cellulose-rich waste products?

Initially, Melodea extracted CNCs using waste products from the paper and forestry industries. However, these waste materials contain contaminants and additives, meaning they need to undergo an economically and environmentally costly treatment before they can be fed into the extraction process. For this reason, the company now exclusively uses forestry wood pulp instead. This raises a question around the sourcing of the pulp and whether it's sustainably and responsibly obtained. But it also offers a window of opportunity for tech companies like Melodea to explore a feasible method for integrating cellulose-rich waste materials into their feedstock.

How much water is needed to extract CNC, and which chemicals are used?

CNC is chemically extracted using Melodea's technology – the material is chopped up and placed in a reactor which uses acid to isolate the fibres. But which acids are used, and do they have any molecular impact on the final product? CEO Shaun Lapidot has stated that after CNC is extracted it's washed to separate the acid, so it's also worth finding out how water-intensive the process is. Acid and water usage are important metrics for determining sustainability, and these questions should be adequately addressed to ensure that the product lives up to its green claims.