Researchers at the Indian Institute of Science (IISc) in Bengaluru have pioneered a new, eco-friendly foam made from bio-based materials that breaks down in landfills without harming groundwater, providing a sustainable substitute for conventional plastic foams. With global production of plastic foam at around 2.3 million tonnes annually and less than 1% of it being recycled, plastic waste in landfills continues to escalate, posing environmental hazards. In response, a team from IISc’s Department of Materials Engineering, under the guidance of Professors Suryasarathi Bose and Subodh Kumar, has engineered a biodegradable foam tailored for packaging in the Fast-Moving Consumer Goods (FMCG) sector. The foam is crafted using bio-based epoxy resins derived from non-edible oils—approved by the US Food and Drug Administration (FDA)—and hardeners sourced from tea leaves. This composition reduces dependency on fossil fuels and non-recyclable materials while delivering high compressive strength.
The researchers highlighted that producing 10,000 units of traditional plastic foam cups generates approximately 308 kg of greenhouse gases. India’s foam market, worth USD 7.9 billion in 2023, is forecasted to reach USD 11.1 billion by 2032, expanding at a 3.85% compound annual growth rate (CAGR). Despite its essential role in FMCG packaging for being lightweight and protective, conventional foam materials such as expanded polystyrene (EPS) and polyurethane (PU) are non-biodegradable, often accumulating in landfills and causing environmental harm.
Researchers Sampath Parasuram, Akshay Sunil Salvi, Supriya H, and Sandeep Kumar Singh elaborated that the new bio-based foams possess chemical bonds designed to break and reform under specific conditions, enabling them to be reprocessed mechanically or dissolved in eco-friendly solvents within hours. They emphasized that, unlike traditional foams that may take centuries to degrade, these bio-derived foams decompose quickly in landfills without contaminating groundwater. The team has also filed for a patent to protect this innovative technology. While the current production cost of bio-based foam remains high, Bose anticipates that rising demand will gradually lower expenses. He noted, “With stricter regulations against polymer-based foams, we expect bio-based foams to become widely available within five years. Sustainable packaging solutions are essential, as landfills are increasingly filled with synthetic materials.
