REBAPO aims to develop a recyclable high-barrier packaging solution for freeze-dried food products requiring exceptionally long shelf life. The project addresses one of the major challenges in sustainable packaging: replacing complex, non-recyclable multilayer laminates containing aluminium and incompatible polymers with a recyclable mono-material alternative while maintaining food safety, durability, and product protection for up to 5-7 years. 

Drytech's freeze-dried meals are currently packed in high-performance, non-recyclable packaging structures that provide excellent protection against oxygen, moisture, light, and aroma loss. As future European and Norwegian regulations increasingly require recyclable packaging solutions, there is a critical need for innovative packaging designs that combine circularity with demanding functional requirements. 

Objectives

The main objective of REBAPO is to develop a safe, mechanically recyclable food packaging format that delivers:

• Extraordinary shelf life of 5-7 years for freeze-dried food products
• Excellent oxygen, moisture, aroma, and light barrier performance
• Reliable sealing and leak-free functionality
• Compatibility with existing recycling infrastructures
• Compliance with Design for Recycling guidelines and RecyClass requirements
• Food contact compliance and consumer safety throughout the product lifecycle 

Research and Innovation

The project investigates advanced mono-material polyolefin-based packaging concepts combined with innovative barrier technologies capable of replacing conventional aluminium-based laminates. Research activities include:

• Benchmarking existing recyclable packaging solutions
• Development of high-performance laminate formulations
• Packaging format and sealing technology optimisation
• Recyclability verification according to RecyClass protocols
• Shelf-life, food safety, and sensory performance evaluation
• Full-scale industrial validation and field testing

A key challenge is achieving the barrier performance required for long-term storage while ensuring the packaging remains compatible with mechanical recycling streams. The project therefore combines material development, processing optimisation, recyclability assessment, and end-use validation within one integrated value-chain approach.

Expected Impact

Successful implementation of REBAPO will support the transition from linear to circular packaging solutions by enabling recyclable packaging for high-value food applications where recyclability has traditionally been difficult to achieve. The results are expected to have transfer value beyond freeze-dried meals and can potentially be applied to other food packaging formats requiring demanding barrier properties and extended shelf life.

The project contributes directly to reduced packaging waste, increased plastic recycling rates, improved resource efficiency, and strengthened competitiveness for Norwegian industry. It also supports European Circular Economy ambitions and future packaging sustainability requirements. 

Consortium

REBAPO brings together partners representing the entire packaging value chain:

• Drytech AS – Project owner and producer of freeze-dried food products
• Norner Research – Main R&D partner responsible for material development, testing, and recyclability assessment
• MPack AS – Packaging supplyer
• Skala Maskon – Packaging machinery and process adaptation
• Ragn-Sells – Collection, recycling, and circularity implementation
• The Norwegian Defence Estates Agency (NDEA) – End-user representative supporting field testing and waste management solutions

Norner's Role

Norner is the primary R&D partner in REBAPO and leads the development and evaluation of recyclable high-barrier packaging concepts. Activities include material formulation, barrier technology assessment, pilot-scale processing, recyclability verification, food packaging performance testing, and support for industrial implementation. Norner also ensures that developed solutions comply with evolving Design for Recycling requirements and Circular Economy principles.

Project Manager: Tomasz Czulek

Funding received from: IPN