Seaweed plastic packaging is falls into the category of eco-friendly packaging that is rapidly gaining attention as the perfect replacement for petroleum-based plastics. Unlike traditional plastics that are made from crude oil and natural gases, releasing greenhouse gases and creating long lasting plastic pollution, seaweed plastic is compostable and biodegradable without leaving behind microplastics.
As we are aware about the negative consequences of single-use plastics, innovators are searching for eco-friendly packaging materials that will have a minimum impact on the environment. One of them is seaweed plastic, which has been created from marine algae or plants. It is non-toxic, biodegradable, sustainable and in some cases, edible.
Introduction
Plastic pollution is one of the biggest environmental problems that our planet is facing today.
Every year, more than 400 million tons of plastic waste are generated and without proper recycling, most of it ends up in landfills, rivers and oceans, creating plastic pollution.
Shockingly, only 10% of all the plastic ever produced has been recycled and the remaining 90% accumulates in the environment, polluting ecosystems, harming wildlife and even further contaminating our food chain.
If it is continuing, by 2050 there could be more plastics in the ocean than fish.
What makes petroleum-based plastic even more concerning is that it is manufactured by using additives like BPA (Bisphenol A) and phthalates, which are well-known for their carcinogenic effects.
These toxic substances can leach from plastic packaging to our food and drinks, increasing our risk of cancer.
The recent rise in cancer cases is a classic example of how plastic packaging is silently killing us.
Moreover, after 500 to 1,000 years, accumulated plastics break down into microplastics and contaminate groundwater and the food chain.
As a result, these microplastics can build up in our organs over time, leading to serious health issues or even organ failure.
Scientists were shocked to find microplastics in a human foetus during a medical examination after death.
These tiny particles had crossed the blood-brain barrier and for your information, blood-brain barrier is the body’s strongest natural filter designed by the God to protect babies in the mother’s womb.
If microplastics can cross this protective barrier, it shows how serious the problem is.
Then, what is the solution?
Seaweed is nature’s gift, available abundantly, renewable and perfect for making biopolymers that are safe for humans, wildlife and the planet. Unlike conventional plastics, seaweed-based plastic packaging is home compostable and increases the soil health on disposal.
What Is Seaweed?
Seaweed is a marine plant or algae that grows in oceans, seas and even in freshwater. It comes in many forms and colours, like red, green and brown.
Unlike land crops, seaweed doesn’t need fertilizers, pesticides or freshwater to grow faster. Additionally, it absorbs more carbon dioxide, produces oxygen in water and supports marine ecosystems, making it one of the most sustainable crops on Earth.
From centuries, seaweed has been used in food, medicine, cosmetics and agriculture, but now it is used as a sustainable packaging material by many start-ups.
What is Seaweed Plastic Packaging?
Seaweed plastic packaging is a type of bioplastic made from seaweed extracts. It looks and feels like traditional plastic, but decomposes naturally in just 180 days without leaving behind microplastics.
Since it is made from algae/plant, this material is safe, biodegradable, compostable and renewable. Unlike traditional plastics, which can persist in the environment for centuries, seaweed plastic packaging decomposes naturally in soil without leaving behind toxic residues.
Seaweed plastic pellets are used to make films, wraps, sachets, straws, containers and many more packaging items. In certain cases, packaging material made from seaweed can be edible, making it a perfect choice for the food, pharmaceutical, cosmeceutical and beverage industries.
Types of Seaweed
Seaweeds are classified into 3 main categories based on their colour and composition.
Red Seaweed (Rhodophyta): These are usually small, and ranging from few centimeters to a meter. Generally, they cover rocks in lower tidal zones and can appear purple or brownish-red. Common genera include Porphyra, Gracilaria and Gelidium.
Brown Seaweed (Phaeophyta or Ochrophyta): Brown seaweeds are generally larger than red seaweed, such as the giant kelp (Macrocystis) which can grow more than 30 meters. Brown seaweeds are commonly found on rocky shores in colder coastal waters. They play a vital role in marine ecosystems by providing food, shelter and oxygen to many ocean species.
Green Seaweed (Chlorophyta): These are typically smaller and include species like Ulva (sea lettuce) and Caulerpa. Green seaweeds are closely related to land plants and are commonly found in shallow coastal waters.
Each type of seaweed has unique characteristics, habitats and ecological roles. For example, brown seaweeds like kelp form underwater forests that provide shelter and food for marine life, while red and green seaweeds are important food for marine creatures and humans.
Composition of Seaweed
Seaweeds are rich in nutrients and bioactive compounds, they are useful not only for ecosystems, but also equally important for the industries, like food, medicine and sustainable packaging.
Polysaccharides like agar, carrageenan and alginate are widely used in many industries as a gelling, thickening and stabilizing agents.
Proteins and Amino Acids: Seaweed contains a variety of proteins and amino acids, which can be used for different therapeutic purposes.
Vitamins and Minerals: Seaweeds are high in iodine, calcium, magnesium, potassium, iron and vitamins A, C, E, and B12.
Antioxidants and Pigments: Seaweed contains natural pigments, such as chlorophyll (green), fucoxanthin (brown) and phycoerythrin (red), which give it distinct colours. These antioxidants protect the body from harmful free radicals.
Dietary Fiber: Seaweed is an excellent source of soluble and insoluble fiber.
How to Make Seaweed Plastic?
Turning seaweed into plastic is an exciting process. Let’s discuss its step-by-step process.
1. Seaweed Farming
The production process starts from the ocean, where seaweed is cultivated or farmed. Seaweed farming is environmentally friendly because it doesn’t require land, freshwater, fertilizers or pesticides. Generally, farmers grow seaweed on ropes or nets that are suspended in the seawater, where it absorbs carbon dioxide and nutrients to release oxygen in water. Once it matures, farmers can harvest the seaweed several times a year, making it the best renewable and abundant resource.
2. Harvesting and Cleaning Process
After harvesting, the seaweed is thoroughly washed with clean water to remove sand, salt and any marine debris. Clean seaweed is then dried either under the sun or in special drying machines.
3. Grinding and Extraction
The dried seaweed is crushed into a fine powder to extract valuable components, like polysaccharides.
Hot Extraction Process:
To extract these polysaccharides (like agar, carrageenan, or alginate), seaweed is boiled in water. After boiling, the mixture is filtered/centrifuged to separate dissolved polysaccharides from solid residues.
4. Concentration and Purification
This filtered solution is concentrated by evaporating excess water. This process increases the thickness of solution, making it easier to handle. To purify it further, alcohol (like isopropanol) may be added to separate the useful polysaccharides. These polysaccharides are then washed and dried for making bioplastic.
5. Making the Seaweed Plastic
Now comes to the creative part of bioplastic manufacturing.
Mixing Ingredients
The concentrated seaweed extract is mixed with plasticizers, like glycerin, potato starch or corn starch to give mechanical and functional properties to bioplastic.
Other natural additives can also be added to reinforce the resulting material.
For example, essential oils can be added for antimicrobial properties, natural polymers like cellulose or plant starch can also be added to improve strength and water resistance.
Sometimes, natural dyes or colourants are added for visual appeal.
Heating and Blending
Heat the mixture at around 100°C to blend all the components uniformly. Finally, a smooth and thick jelly-like structure will be achieved for moulding.
6. Moulding
This hot blended mixture is either poured into moulds or on to flat surfaces, depending on what we want to make.
For thin films (like wraps or shopping bags), the mixture is evenly spread out on a flat non-sticky surface.
For rigid items (like cups, straws or containers), it is poured into moulds.
7. Cooling and Drying
After moulding or spreading, the seaweed plastic is allowed to cool and dry. This can take from few hours to several days, depending on the thickness and the type of formulation.
You can dry the seaweed plastic at room temperature (around 25°C).
8. Final Touches
Once dried, the seaweed plastic is removed from the moulds or flat surfaces. It can be cut, trimmed or further processed based on the specific applications.
9. Quality Control
Before seaweed-based plastic is ready for practical use, it goes for various testing to ensure it meets quality standards. These tests help manufacturers to modify the material for strength, flexibility, shelf life and compostability.
Here are some key tests:
Tensile Strength – It is used to measure how much force the plastic can handle before it breaks.
Elastic Modulus – It is used to check how stiff or flexible the material is.
Elongation at Break – It is used to check how far the plastic can stretch before it breaks.
Water Vapor Transmission Rate (WVTR) – It is used to calculate how much water vapor passes through the material. It is important for food and pharmaceutical products.
Oxygen Transmission Rate (OTR) – It is used to check how much oxygen passes through the material. By reducing the oxidation process, shelf life can be increased for the packaged products.
Water Resistance – It is used to ensure that the packaging material will not dissolve or weaken when exposed to high humidity.
Compostability Test – It helps to confirm that the material is compostable within 180 days.
If the results are not proper then manufacturers can revise the formula to achieve the perfect balance of strength, flexibility, barrier performance and eco-friendliness.
Properties of Seaweed Plastic Packaging
Seaweed-based plastics have enough mechanical and functional properties, making them an ideal material for sustainable food packaging.
Elastic Modulus
Material’s stiffness or flexibility is measured in terms of elastic modulus. Seaweed plastics can have an elastic modulus from 1,300 MPa to 2,400 MPa, based on how it is made. For example, a seaweed-based film without plasticizer can give a modulus of 2,417 ± 197 MPa, indicating its good rigidity and structural integrity.
Tensile Strength
From this value, we can know, how much a material can be stretched before it breaks. Seaweed plastics possess tensile strengths from 10 and 48 MPa. These values are comparable to some conventional plastics, such as low-density polyethylene (LDPE) and polypropylene (PP), making seaweed plastic suitable for food packaging applications.
Elongation at Break
Elongation at break shows, how far material can be stretched before it breaks. For seaweed plastic, it is ranging from 3% to 10%, which again depends on its formulation. This value is sufficient for many packaging applications.
Other Important Properties
Water Vapour Permeability: Seaweed films can be designed with low WVTR (water vapour transmission rate). This value is very crucial for pharmaceutical packaging applications.
Biodegradability: Seaweed plastics are fully biodegradable and compostable, which breaks down naturally without creating microplastics.
Thermal Stability: Adding seaweed to other bioplastic blends can improve the thermal stability of composite plastic materials. Means they can be used for restaurant food packaging. In certain composite plastics, the melting temperature is higher than regular polypropylene (PP), making seaweed composite plastics more heat-resistant and suitable for a wider range of applications.
Antioxidant and UV Resistance: Some seaweed plastics naturally provide antioxidant and UV resistance properties that can help to increase the shelf life of food packages.
Compostability Standards for Seaweed Plastic
Seaweed packaging is generally both biodegradable and compostable, meaning it can break down naturally in the environment. To be certified as compostable, materials must comply with specific standards, as mentioned below:
EN 13432 (Europe)
ASTM D6400 (USA)
Generally, seaweed plastic packaging complies with above standards.
Benefits of Seaweed Plastic Packaging
Seaweed plastic packaging possesses many benefits in comparison to petroleum-based plastic packaging.
Biodegradability and Compostability: Seaweed plastic breaks down naturally and quickly without creating harmful microplastics in the environment. When composted, it can even enrich the soil, supporting a zero-waste packaging approach.
Renewable Resource: Seaweed grows rapidly and can be harvested multiple times a year without the need for land, freshwater, fertilizers or pesticides. This makes it a truly sustainable and scalable resource.
Chemical Free Material: Unlike traditional plastics that often contain harmful chemicals like BPA or phthalates, seaweed plastic is completely free from this carcinogenic substance, making it a safer choice for food, pharma and cosmetic applications.
Edible and Safe: Apart from biodegradability and compostability, edible seaweed packaging can also be prepared. This innovation enhances sustainability and reduces waste, especially in single-use applications such as food wraps, beverage cups and takeaway containers.
Edible packaging eliminates the need for disposal. Loliware’s edible cups are an excellent example of zero waste packaging, which are designed by considering functionalities and compostability. These edible cups are ideal for events like Thanksgiving parties or social gatherings, where disposable plastic cups are commonly used.
Versatile and Flexible: Seaweed plastics can be manufactured into various forms, like films, wraps, pouches, boxes and even edible coatings, making it suitable for a wide range of packaging purposes, especially in the food industry.
Seaweed-coated paper materials offer a sustainable alternative to traditional plastic-lined containers.
These materials are not only compostable but also eliminate the need for conventional food packaging, reducing environmental impact. Their flexibility allows easy customization for different products while supporting circular economy goals.
Environmental Impact: Seaweed farming absorbs more carbon dioxide than any other land-based crop, helping to mitigate climate change and ocean acidification. The overall production process uses less energy and resources compared to petroleum-based plastic manufacturing, further reducing the carbon footprint.
Functional Properties: Seaweed-based plastic packaging can provide good moisture and oil resistance that increases the shelf life of food. Additionally, it offers antimicrobial properties because of its bio-components.
No Competition with Food Crops: Unlike other plant-based bioplastics, like corn starch and sugarcane, seaweed plastic doesn’t compete with food crops. Corn and sugarcane are essential food sources for humans and using them for plastic can impact on food prices.
In summary, seaweed plastic is a safe and sustainable packaging option that protects human health, supports the environment, combats climate change and helps to achieve a green lifestyle.
Disadvantages of Seaweed Plastic Packaging
High Cost: Seaweed plastic is costly as compared to traditional plastics. This is because of manual processing, limited infrastructure and new technology.
High Cost: Seaweed plastic is costly as compared to traditional plastics. This is because of manual processing, limited infrastructure and new technology.
Less Durability: Seaweed plastics are less durable due to its biodegradable nature. In comparison with traditional plastics, it possesses low mechanical and functional properties, making them less suitable for special packaging applications, like tea bag packaging.
Limited Availability: Seaweed plastic is not completely developed with its full potential and yet not available globally.
Seaweed Products Available in the Market
Edible Packs: Edible packaging materials for water, sauces and fruit juices are developed by Notpla and Evoware. Product can be consumed along with the pack, eliminating packaging waste.
Edible water pods from Notpla is the best example of zero waste packaging. This bubble pack offers an innovative solution to replace single-use plastic bottles, reducing plastic pollution.
Plastic Films: To wrap fruits, salads, sandwiches and other consumable goods, seaweed-based films are available. This film has enough barrier properties to protect the items from spillages.
Food Containers: Some companies are now developing food boxes and takeaway containers which are coated with plastics derived from seaweed. Seaweed-based plastics are strong and biodegradable, making them excellent choice for cafés, restaurants, and food delivery services.
Straws and Cups: Edible straws and cups are available from the companies, like Loliware and Evoware.
Personal Care and Cosmetics: Seaweed-based films and pouches are gaining popularity in cosmetic packaging. These materials are home compostable and offer sufficient protection for products like creams, lotions, and shampoos.
The face mask you can peel off is made from seaweed extracts, which are rich in bio-active substances. What makes it more sustainable is the pouch and sachet, which are also made from seaweed plastic. Thus, we have truly a zero-waste product-packaging system combination.
Seaweed Plastic Cost
Currently, seaweed plastic packaging costs are more than conventional plastic due to its newness and limited production scale. However, with the ongoing technology advancement and larger production volumes, costs are expected to come down, making seaweed packaging more competitive in the future market.
On average:
Seaweed Film Packaging:
₹7–12 per sachet
➡️ ~$0.08 to $0.14 per sachet
(Compared to plastic at $0.02 to $0.05)
Seaweed Straws:
₹5–10 per straw
➡️ ~$0.06 to $0.12 per straw
(Compared to plastic at $0.01 to $0.02)
Seaweed Plastic Market Analysis
The global market for seaweed packaging is growing rapidly, which is driven by below mentioned factors.
The global seaweed packaging market is projected to grow at over 15% CAGR in the next 5 years.
Rising Consumer Awareness: More consumers are looking for eco-friendly packaging nowadays.
Corporate Commitments: Big corporate players are pledging to reduce plastic pollution by exploring biodegradable packaging materials.
Government Regulations: Bans on single-use plastics and tax credits are accelerating the shift towards green packaging, like seaweed plastic packaging.
Investment in Innovation: Start-ups and established companies are investing more in research and development to improve the functionalities of seaweed plastic.
Seaweed Plastic Packaging Manufacturers
Below are some of the industry leaders in seaweed plastic packaging and their innovative sustainable stories.
Notpla (UK): Notpla started its journey in 2014 by producing edible seaweed bubbles called Ooho. The co-founders, Pierre-Yves Paslier and Rodrigo García González expanded their products from Ooho to bio-films, bio-coatings and even takeaway boxes.
Evoware (Indonesia): Known as one of the pioneers of edible seaweed packaging, Evoware specializes in creating wraps, sachets and cups. They work toward plastic waste reduction with a goal to replace traditional plastic packaging with biodegradable or even edible options.
Sway (USA): Sway is an American start-up focusing on single-use flexible packaging. They create home compostable items made from seaweed.
Loliware (USA): Another American start-up that proudly states that they provide alternatives to plastic disposables through their LIon straws and shake cups.
B’ZEOS (Spain): Specializing in films and pouches, B’ZEOS works towards the replacement of plastic used in various industries by innovating biodegradable solutions.
Zerocircle (India): This Indian start-up is leading in seaweed-based films and pouches by creating biodegradable packaging products. This aligns with India’s increasing focus on sustainable alternatives.
Future Advancements in Seaweed Biopolymer Technology
Seaweed-based biopolymer technology is still in its early stages and growing rapidly with the help of technological advancement.
1. Improvement in Material’s Properties
Scientists are developing composite plastic material by mixing seaweed extracts with other bio-polymers (like mango peel, cellulose or starch) to increase the strength, flexibility and barrier properties.
2. Edible Pharmaceutical Packaging
Seaweed-based packaging can be explored as a sustainable solution in pharmaceutical sector.
For example, cough syrup can be encapsulated in pack of a 5ml using seaweed-based packaging.
This could help pharmaceutical companies to reduce plastic pollution while offering dose accuracy and patient convenience.
These biodegradable and interactive packs would be helpful for children for taking medicine playfully while reducing plastic waste and overdosing risks.
However, this concept is under development, since the pharmaceutical industry follows strict regulatory standards for packaging materials and product stability.
3. Cost Optimization
With advancement in the technology, cost of the seaweed plastic packaging comes down at a significant rate.
Conclusion
Seaweed plastic packaging is a promising solution to reduce plastic pollution. By using the power of this natural material, we can create packaging material which is safe for people and planet.
Of course, there are few challenges to overcome, like cost, scalability and performance, but ongoing research and development definitely solve these hurdles.
If you noticed any important points that I missed, please leave a comment below!