A solution to the plastic waste crisis: DHBW Karlsruhe launches the ‘Bio-Lam’ project

Paper that is so strong and durable that it can be used to make products that were previously manufactured from plastic or wood: the solution is called PLAFCO (Plastic Free Paper Composite) – an innovative fibre-reinforced composite material whose development began at the Baden-Württemberg Cooperative State University (DHBW) in Karlsruhe more than ten years ago. Behind this lies a key challenge: whilst plastic is indispensable for many applications, it poses significant environmental problems due to its reliance on fossil raw materials and the generation of long-lasting waste. The search is therefore on for materials that combine functional stability with genuine environmental sustainability.

This is precisely where PLAFCO came in. Following research, the filing of a patent, the award of the NEO2020 Innovation Prize and the development of a pilot plant, the research is now moving into the next phase: the Bio-Lam project aims to develop sustainable, bio-based laminates using PLAFCO from 2026 onwards.

How paper became a new material
The development of PLAFCO began in 2013 as part of the EU research project COMPAC. By 2016, the foundations for this novel material had been laid and a patent had been filed. The aim was to modify paper in such a way as to create a stable and resilient composite material.

The solution is based entirely on cellulose. During production, the paper is chemically treated in such a way that some of the cellulose on the surface of the fibres is dissolved. This allows the fibres to bond with one another in a different way. As a result, the material gains significantly greater strength, whilst remaining very similar to its source material, paper.

“We wanted to develop a fibre-reinforced composite material made entirely from plant-based materials and which is biodegradable,” explains Prof. Dr Jukka Valkama, Head of the Sustainable Science and Technology – Paper Technology / Packaging Technology degree programme at DHBW Karlsruhe. “And we have succeeded.” The research findings have opened up a wide range of potential applications. Among other things, packaging has been developed for tissues, drink cartons, straws, cutlery and other single-use products.

From research success to a pilot plant
A key milestone was winning the NEO2020 Innovation Award from the Karlsruhe Technology Region. The material, developed by Valkama, staff and students at DHBW Karlsruhe, was recognised in the bioeconomy category. The jury particularly commended PLAFCO’s potential as a substitute for plastic-based packaging and single-use products.

The next major step came in 2024: the research project “Pilot Plant for PLAFCO” at DHBW Karlsruhe was selected for funding as part of the DATIpilot roadshow “Innovation on Stage”. In collaboration with the start-up Junitec GmbH, which was responsible for the design and construction, a pilot plant was built and tested. Within around eleven months , a ‘proof of product’ was thus achieved : PLAFCO could now be produced not only in the laboratory but also in a technical plant.

Moving to the next stage of development with Bio-Lam
The development will not come to an end with the completion of the PLAFCO project in January 2026. In the Invest-BW project ‘Bio-Lam’, which runs from 2026 to 2028, the material will be further developed for new applications. The aim is to produce sustainable, bio-based, solid and stable laminates with basis weights of 1,000 to 3,000 grams per square metre, using PLAFCO and environmentally friendly binders. These are intended to replace sturdier plastic or wooden products such as ice lollies, coffee stirrers or thin wooden panels in furniture .

A key research question in this context is the binder used. On the one hand, it must be biodegradable; on the other, it must provide sufficient strength to ensure that the finished laminate meets the relevant requirements. “The next challenge is to achieve both sustainability and functionality at the same time,” explains Valkama. “A material may be biodegradable yet too unstable for a specific application. Or it may be very stable, but achieve this stability through components that run counter to a sustainable circular economy. At Bio-Lam, we are looking for a solution that combines both: a bio-based, high-performance material and a binder that also aligns with our sustainability goals.”

The development of PLAFCO demonstrates how a research idea can evolve into a concrete material innovation through several stages of development. Following basic research, a patent, awards and the establishment of a pilot plant, the next challenge now lies ahead: further scaling up and the development of new applications. With Bio-Lam, DHBW Karlsruhe is continuing along this path and investigating how high-performance yet sustainable laminates can be produced from the cellulose-based PLAFCO material.