Reinvest 2050 » Muoto™ packaging from wood

Muoto™ packaging from wood

Project description

Plastic is the most widely used material in food packaging, typically, based on fossil raw materials. Recycling plastic packaging, especially with its composite structure, is often challenging, resulting in only a small portion being recycled globally. The takeaway sector heavily relies on bagasse-based packaging, mainly imported from Asia to the EU. These factors create opportunities for new packaging solutions. This is why Metsä Group, in partnership with Valmet, started developing a new wood-based packaging solution. At the heart of the ongoing project is a demo plant in Äänekoski, Finland, which opened in May 2022.

The implemented solution

Muoto™ products are made from renewable wood fibres using an innovative manufacturing technology, allowing multi-layered, lightweight, yet sturdy packaging. The products are directly three-dimensional, free from harmful chemicals, such as PFAS, making them suitable for food packaging. The manufacturing method is resource-efficient, modular and fully automated. Muoto™ products are directly finished and do not require further processing down the supply chain, ready for delivery to the end-users. After use, they can be recycled alongside cardboard.
The drying method is efficient, and the products are of high quality and have a smooth surface. Production can be integrated to the unit producing the pulp(s).

The key hurdles solved

• Securing freedom-to-operate remains an ongoing task, including during the demo phase.
• An important area is finding a business model that is competitive on a global market, considering similar materials produced outside the EU and imported to the region.
• The project is still in the demo phase. Many non-technological hurdles, such as environmental permits, are not yet relevant.

Key Suppliers / Partners

Whereas Muoto™ is a Metsä Spring (Metsä Group) product, the groundbreaking manufacturing technology is an outcome of close collaboration between Metsä Spring and Valmet.

“Packaging of goods is a huge business area that continues to grow and evolve. A large proportion of consumer and food packaging is made of plastic, which typically relies on fossil raw materials and is often imported from outside the EU. Moulded fibre products offer an alternative to these, and we have further developed and improved this technology.
The production of Muoto™ packaging products is integrated in a pulp-producing mill, which offers many benefits: carbon dioxide emissions, per tonne of Muoto™ product, are low, Muoto™ can be recycled and is rigid but still lightweight, which improves raw material efficiency and reduces transport emissions.
Developing a new product is inspiring and, in doing so, we have found top professionals for our team and as our partners.”

Jarkko Tuominen
Vice President, Projects, Metsä Spring

The Project’s Achievements:

Investment
So far, Metsä Group and main partner Valmet have invested over 20 million euros in the project.
Business Finland has supported the project with grant funding.

CO₂ emissions saved
Muoto™ products are made from pulp from Metsä Group’s Äänekoski bioproduct mill. It has fossil CO₂-eq emissions per tonne, approx. 30% lower than the average European pulp mill. All chemicals and additives are assessed for suitability for food contact and compliance with the relevant regulations and recommendations (see Sustainability on muoto.io).

Any other sustainable benefits
The Muoto™ concept has other sustainability benefits:
• Muoto™ is made for purpose.
Our wood-based products can replace fossil-based or sugarcanebased packaging alternatives in selective applications, in align with our product development and product performance.
• Uncoated Muoto™ products are easy to recycle and are biodegradable, if recycling them is not possible.