Queen Mary University of London and Archipelago Technology Group Limited KTP 24_25 R4

Moulded-fibre containers—the kind used for takeaway meals or egg cartons—cannot yet replace plastic packaging because their porous surfaces soak up moisture and grease, and no existing method can apply a waterproof barrier coating to their complex 3D shapes without touching them. Current coating techniques rely on spraying or dipping, which either miss recessed areas or clog the fibre structure. This project will develop a noncontact technology that deposits thin barrier coatings evenly onto curved, textured moulded-fibre surfaces. The approach uses precise deposition methods that avoid physical contact, preserving the container’s shape and fibre integrity while sealing it against liquids and oils. If successful, the technology would allow paper packaging to match plastic’s performance in food and consumer goods—without the waste. Moulded fibre is already biodegradable and made from recycled material; the missing piece has been a reliable, scalable way to make it waterproof. This could shift supply chains away from single-use plastics in sectors such as fast food, grocery packaging, and online delivery, where plastic liners currently dominate. The work is applied engineering, not fundamental science. Its immediate goal is a manufacturing process that works at industrial speed and cost.