Since the 1970s plastics have taken over the world. They became popular for they are cheap, diverse and have a variety of uses. It only came later that we realized that plastic also creates a big problem once it becomes waste. As it is not biodegradable, it piles up in landfills and oceans, leaving harmful substances around and polluting our environment. 

Plastic production has grown faster than that of any other material. However, according to a new OECD report, only 9% of it is recycled. All other plastic waste either goes to landfills, is incinerated, or mismanaged and uncontrolled. It also has a major impact on aquatic environments. The report found that in 2019, 6.1 million tonnes of plastic ended up in our waters. It is now estimated that oceans and seas hold around 30 Mt of plastic waste, while there is a further 109 Mt in rivers. Single-use plastics, which became part of our everyday lives, cause the biggest challenge as these constitute half of all plastic produced, according to UNEP. 

As recycling does not prove to be as useful as it intends to be, scientists and engineers now look for other options: the goal is to create plastic-like materials that are biodegradable. However, many attempts and initiatives failed to become widespread. As Afshar - co-founder and CPO of Shellworks - explained, “while some solutions exist, 92% of biodegradable solutions on the market require industrial composting. This infrastructure is unavailable in most regions, which in turn has limited the uptake by companies.” 

Afshar, who was a guest at Staiy´s webinar on biomimicry back in December 2021, talked about how their latest innovation, Vivomer, might transform packaging as we know it now. To achieve their goal, Shellworks turned to nature: “Nature is the ultimate biologist and the ultimate chemist”, says Afshar. “What we do today is working with nature.” 

Shellworks is a UK based company founded in 2020 by Insiya Jafferjee, Amir Afshar and Edward Jones. The three are Imperial College graduates who met on the Innovation Design Engineering master's programme. They were fascinated by bio-based technologies, which became the center of what they do now in Shellworks. 

Shellwork uses two approaches in their development: biomimicry and biosynthesis. The former means they learn from nature, how it works and what it does, while the latter refers to a collaboration between nature and people. They expertize in microbes, and develop all their products in-house. While working with microbes, they found that by simply tailoring the feedstock and growth conditions, they can get different structural formations and properties. Next they extract the biopolymers to create materials. 

Vivomer is their latest innovation which may be the solution to plastic waste. It is a fully vegan and compostable material, created with the help of microbes. During its lifespan the packaging is shelf stable. However, once disposed of, microbes abundant in soil and marine environments consume the material, leaving no microplastics behind. “It is a process through which it allows bacteria to feed on it”, says Afshar. Thus the product will biodegrade in any natural environment without the need of any special conditions. 

Shellworks also designed a line of ready-made products made out of Vivomer. For now, they focus on designing sustainable packaging for the beauty and personal care industry, as there are few alternatives to plastic in these areas. They have a range of packaging options which can be used by companies: from lipstick tubes and cream containers all the way to bottles and oil dispensers. 

Shellworks’ amazing innovation comes with several benefits: 

Unlike many other plastic-replacement materials, Vivomer is mass manufacturable.

-As it is a fully organic product, it is petroleum free.

-Vivomer is compatible with oils-based and water-based creams and products.

-It doesn´t need any special environment or substances: Vivomer is home compostable within one year.

-As a result of all these, the material has a low carbon footprint.

-Viviomer is also dyeable and printable, making it possible to customize and fit brands´s needs.

-Shellworks´ products are mono-material solutions, unlike usual plastic packaging which are made out of a mix of different plastics and other materials, making them non-recyclable. 

Shellwork´s innovation might be an important step towards reducing plastic waste. They call themselves “critical optimists'' - believing there is a better way, and constantly trying to improve. While their products are not yet widely available, they prove that there might be a viable option for plastic replacements in the future and we can’t wait to see this project finally completed!