NatureFlex

Percol coffee packaging / Source: Futamura

AsiaCelluloseCompostableEuropeFood & BeverageFood GradeHeat ResistantLeak ProofMoisture BarrierNatureFlexNorth AmericaOil ResistantOxygen Barrier PackagingSealableSouth AmericaTransparentUV-Resistant

WHAT WE SAY:

We all like to see the food we are buying - it helps us trust that we are getting what we are paying for. But being granted this visibility has led to an inordinate reliance on flexible plastic films - over 33.5 million tonnes of incredibly light plastic existing for centuries. Natureflex films could be the answer, made from 90% raw cellulose material and 100% plastic-free when used uncoated.

The films are predominantly industrially compostable - not always a perfect end-of-life solution, although good for anything contaminated with food already. We believe it’s a step in the right direction that offers an intermediary solution for designers.

NatureFlex

WHAT IS NATUREFLEX?

Natureflex by Futamura is a renewable and certified compostable collection of food-grade packaging films derived from regenerated wood pulp Cellulose, sourced from fast growing FSC-certified sources, such as eucalyptus.
The wood pulp is converted to viscose then cast into uncoated Natureflex film. One ton of pulp is required to produce one ton of Natureflex. Most Natureflex films are produced with a minimum of 90% renewable raw cellulose material.
Uncoated Natureflex is not classified as plastic under the EU single-use plastics directive (SUP). Made from a natural polymer, whose chemical structure remains unchanged even after conversion into viscose, uncoated Natureflex can be twisted for use as packaging, as is the case with Quality Street. When coated, Natureflex is considered a single-use plastic due to the coating containing a small amount. As there is no lower limit for plastic-use within coatings in the SUP, this ensures it is within scope.
The range includes transparent, metallised, coloured and opaque films, which can be printed using conventional printing techniques. Inherent properties of the films include a high heat resistance, natural anti-static properties for machining, and resistance to chemicals, greases, oils and fats. The films can be machined at a temperature comparable to PET.
All film types are certified for industrial composting to EU standard EN 13432. Some film types are certified for home and industrial composting through TÜV. In industrial composting trials, at least 90% of Natureflex had degraded within 45 days. The films compost into CO2, water, mineral salts and new biomass, and for composting certification there must be no negative chemical effects on the final compost. Some films have been shown to degrade as required by ISO and TÜV standards in marine and anaerobic environments, too.
We have asked the company what the remaining 10% is made from and are awaiting response.

KEY PROPERTIES:

Compostable
Food Grade
Heat Resistant
Leak Proof
Moisture Barrier
Oil Resistant
Oxygen Barrier
Sealable
Transparent
UV-Resistant

INDUSTRY:

Food & Beverage
Packaging

AVAILABILITY:

Mass Market

DIVE DEEPER:

Futamura claims that an extraordinary 32% of all plastic packaging waste leaks into ecosystems, proving fatal to marine life and breaking down into microplastics, negatively affecting our food chains.
Launched in 2008, by Innovia Films, Natureflex was acquired by Futamura in 2016 due to a rising demand for renewable and compostable plastic-film alternatives. The global biodegradable film sector was valued at an estimated USD 1 billion in 2021, and is expected to grow to a value of USD 1.4 billion by 2025.
Unlike other renewable biobased polymers, which come from corn, potatoes and wheat, Natureflex is based on cellulose - one of the most naturally abundant organic materials in the world. Despite this, Futamura can only create 37,000 tonnes of cellulose film per year at present. Meanwhile, Statista predicts that 33.5 million metric tons of flexible plastic film will be created globally in 2022 alone.
Futamura offers six key types of Natureflex film - uncoated, semi-permeable, barrier, metallised, labels and heat resistant, and as with their plastic counterparts, the films can be heat-sealed, printed, and provide a barrier against water vapor, gases and aroma.
Suitable applications for Natureflex include bakery items, tea and coffee, snacks and dried foods, confectionery, fresh produce, and foodservice packaging. Household names currently using NatureFlex include Teapigs, Percol, Quality Street and nu’cao.
According to Futamura, a Natureflex coffee pack reduces carbon emissions from 0.5 kilograms to 0.28 kilograms (CO2 equivalent per square metre), when compared with a conventional plastic and aluminium composite pack.
Natureflex is manufactured at one of three Futamura production sites in Wigton (UK), Atlanta (US) and Aichi (Japan). In September 2023, the company opened a "state-of-the-art" production line in Wigton in response to growing demand, increasing its production capacity by around 25%.

Quality Street using uncoated, twisted Natureflex / Source: Nestlé

Sample bakery packaging / Source: Futamura

KEY FACTS:

90%

Most Natureflex films are produced with a minimum of 90% renewable raw cellulose material.

33.5 million tn

Flexible plastic films create over 33.5 million tonnes of incredibly light plastic existing for centuries.

45 days

In industrial composting trials, at least 90% of Natureflex had degraded within 45 days.

Key Questions to Ask:

Will it end up in the right waste stream?

Despite being made from wood-pulp and described as transparent paper, Natureflex is not repulpable and therefore not suitable for paper recycling. It is also not suitable for mechanical recycling due to the fact it is not a thermoplastic material. This means a consumer must have access to either a food waste stream or industrial composting facilities to adequately dispose of it. Full recyclability with a system in place to reclaim the product is a better goal.

When is it the right time to use a compostable material?

Check out our Compostable Conundrum report here. The simple question to ask is, does this material act as a conduit to take food waste into the composting food waste stream? If the answer is no, then it probably is the wrong use of this valuable but limited material. If it is yes, then your choice is extremely defensible as it is imperative for us to stop landfilling organic waste that produces methane and other GHGs. Composting is Nature’s circular economy in action.

What finish are you looking for and will this affect the product’s sustainability credentials?

Uncoated Natureflex is more easily compostable than coated and considered plastic free. Additional features such as printing, adhesive reception and heat sealability are gained through extra coating layers. Applying a coating categorises Natureflex as plastic, so to be fully plastic-free it must be used uncoated. Consider if this can work for your application.

Can you move away from single-use?

While an improvement on fossil-fuel derived plastics, Natureflex is still a single-use solution. Explore systems change design, such as in-store refill and prefill for dried food, coffee and tea offerings.

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