Background In Europe there are roughly 60 million tonnes of plastics consumed today. Global plastic production increased from 1.5 million tonnes per year from 1950 to 245 million tonnes in 2008, of which 60 million tonnes were produced in the EU. An estimated 66.5 million tonnes of plastic will be placed on the EU market in 2020 (if no action is taken) and the global plastic production is estimated to triple by 2050. The global packaging market is estimated to be worth €450 billion with plastic accounting for nearly 40% of the market share, followed by paper and board with 30%. With a growth rate of about 6%, the European market for food trays is expected to amount to 10-12 billion trays in a few years, the equivalent of around 2 million tonnes of plastic. In many cases, the packaging gives the product a significantly longer life span, which means that food wastage is reduced. This suggests that there will always be a need for food packaging. The demand, however, for replacing plastic with fibre-based packaging is growing steadily. If production of a fibre-based packaging that creates an oxygen-free atmosphere can be achieved, then there is the potential to break into the market for packaging of fresh food. However, existing paper converting processes struggle to compete with cheap plastic converting processes. The need for developing new converting techniques for fibres that are competitive is clear. Objectives The main objective of DURAPULP for LIFE is to successfully demonstrate the production of 3D formed fibre-composite products based on an innovative and green material called DuraPulp, through the use of Airlaid conversion technology. Specifically the project aims to: Validate the market potential using commercial reference products with chosen potential customers and actors in the value chain (Initial results show a potential for commercialisation of DuraPulp within two years of the completion of the LIFE project); and Further knowledge of Airlaid technology for biocomposites and establish a platform in the value chain for Airlaid thermoforming of high-performance 3D products. Expected results: Demonstration of a new, highly innovative and patented material, DuraPulp, which is renewable and biodegradable, and demonstration of Airlaid technology combined with in line thermoforming for the production of products based on DuraPulp for a range of industry segments; Energy savings by up to 80%, compared to traditional converting techniques such as wet moulding fibre technology; Reduction of global-warming potential (GWP) compared to fossil-based products by at least 65%; At least six products from various end users (and different product segments) validated in the pilot plant; A lifecycle assessment study (LCA) performed on DuraPulp compared to plastics which will aid the measurement of the environmental impact of the material across all lifecycle stages; and Verification of the recyclability options of the material including incineration, recovery by industrial composting (according to the European norm EN 13432) and material recycling in the hydro-pulping process.