How to scale deeptech innovation

The demand for truly sustainable packaging materials is rising at speed. Incoming regulation around plastic packaging and microplastics means brands and manufacturers are seeking a diverse portfolio of materials to replace plastic and differentiate them in the marketplace.

As a result, the race to meet this demand at scale is underway. Innovative companies across the UK are now rapidly scaling up operations to bring new materials to market.

Today, the products available span a range of materials, from seaweed and mushrooms to bamboo. Xampla’s own natural solution, also made from plants, is among the most versatile on offer. Its plant-based formulation means it can even be used to create edible films.

For example, in partnership with meal kit company Gousto, Xampla created the world’s first edible stock cube wrapper. After hitting the online marketplace, this product sold out in just under an hour, illustrating the demand for sustainable products.

But for brands and manufacturers to really put innovation into action, sustainable materials must work seamlessly with existing manufacturing equipment. A real challenge when bringing any new material to market is the capital expense already invested in machinery.

Prioritising compatibility and adaptability, the expert team of scientists and engineers at Xampla have made it possible for the firm's customers to use its material without changing manufacturing processes.

To achieve that we recruited highly specialised chemists, protein and material scientists, analytical methods specialists, product/process developers and scale-up engineers to resolve problems which require a multi-disciplinary approach. 

For example significant product and process development work was required, in collaboration with equipment suppliers and toll manufacturers, and has enabled Xampla to design our materials with the relevant machines in mind. 

Meanwhile, we have evaluated our materials against critical quality control specifications determined by customers by developing robust analytical methods developed in-house and with accredited institutions.

In turn this has allowed us to understand the effect of processing conditions on material microstructure and performance of the final consumer products to meet the wide range of customer requirements coming to our door.

The key has been to understand the design rules for a formulation and a process that allows resin material to be handled by a range of downstream processing equipment and meet the customer requirements. For brands, manufacturers and converters looking to meet sustainability goals in the short term, this is a huge advantage.

For the past 30 years, I have worked developing and manufacturing innovative materials for commercial goods. Previously working at Unilever as Process Development Manager, I saw first-hand what it takes to develop from an initial idea all the way to the supermarket shelf, often on very tight timescales. Although innovation in the lab is incredibly exciting, its true value lies in seeing sustainable materials in use and on shelves. Drop-in materials, that seamlessly replace the functionality that plastic consumers and brands are used to, is an essential challenge to overcome.

Xampla’s aim is to open the door for manufacturers to invest in next-generation solutions to replace the most polluting plastics once and for all.