- Z1ro has created molded fiber packaging from non-wood biomass, including bamboo by-products, hemp hurd, and fallen leaves.
- The fiber-based solution is intended to replace plastic trays, foam inserts, and virgin wood pulp in packaging applications.
- According to Z1ro, its lignin-retaining technology can reduce material consumption, support recyclability, and lessen dependence on forest-based feedstocks.
France-based materials deep-tech company Z1ro has developed bio-designed molded fiber packaging made from non-wood biomass sources.
The company says many manufacturers still rely on virgin wood pulp, plastics, or newer bio-based materials that can present challenges related to price, production scale, and premium appearance. Z1ro is working to provide scalable alternatives for conventional plastic and wood pulp packaging.
Alexander Sobolenko, founder of Z1ro, tells Packaging Insights: “We focus on cosmetics and beauty, consumer electronics, as well as premium gifting, with custom molded fiber inserts and trays that replace plastic trays and foam inserts while protecting and presenting the product.”
“We combine cellulose fibers with locally available bamboo residues, hemp hurd, and fallen leaves. These formulations have been successfully processed on automated industrial thermoforming equipment, demonstrating their suitability for established packaging production technologies.”
Supporting PPWR goals
Z1ro says the rollout of the EU’s Packaging and Packaging Waste Regulation (PPWR) is placing greater demands on the packaging value chain to improve circularity, minimize waste, and broaden its raw material base. Its objective is to create material technologies that satisfy both regulatory expectations and market needs. The company also emphasizes that its process differs from standard pulp manufacturing.
The technology uses biomass engineering methods that retain a portion of the natural lignin found in plant fibers. Z1ro uses this lignin as a natural binder, helping to reduce processing requirements while preserving compatibility with established molded fiber packaging infrastructure.
“Our approach directly supports the PPWR’s priorities of packaging minimization and design for recycling: precisely fitted inserts reduce unnecessary packaging volume, while fiber-based material design prioritizes compatibility with paper recycling. For brands, this offers a concrete route to replace plastic packaging while retaining product protection, premium presentation, and a distinctive material identity,” Sobolenko tells us.
Compatible with existing lines
Based on preliminary technical and economic evaluations, the company says its approach could reduce energy demand, limit chemical consumption, and decrease reliance on forest-derived materials.
The material is also designed to provide distinctive natural textures and visual qualities while running on existing molded fiber production lines.
“The packaging industry is entering a period of transformation. New regulations, shifting consumer expectations, and growing pressure on natural resources are forcing the industry to rethink its material choices,” says Sobolenko.
“Our ambition is not simply to develop another sustainable material — we aim to build a scalable business around non-wood biomass. The next generation of packaging materials will not emerge solely from petrochemicals or traditional pulp production. It will be created at the intersection of material science, local biomass resources, industrial design, and new manufacturing models.”
