Advancing sustainable packaging through robust quality control
The Pulpex project, supported by the Institute for Sustainability as part of its first Innovation Contest and led by Prof Keddie, aimed to develop quality control process for paper bottle manufacturing using computer vision. The project demonstrated the potential of innovation to drive meaningful environmental progress. The project aligned with two United Nations Sustainable Development Goals (UN SDGs), SDG 12 and SDG 13.
The challenge
In 2023, the Institute for Sustainability launched its Innovation Contest to foster collaboration between external organisations and Institute Fellows, co‑creating innovative and sustainable solutions to real‑world challenges. As part of this initiative, Pulpex Ltd. set a challenge to help them develop robust quality control methods for their manufacturing of cellulose-based sustainable packaging for liquids. Pulpex bottles can be recycled in existing paper waste stream, and the bottles manufacturing gives a lower carbon footprint than conventional PET or glass.
The challenge was won by Professor Joseph Keddie’s team, who explored the use of thermal imaging combined with computer vision as a fast and efficient method for monitoring the bottle coating process.
Pulpex Ltd. leads a pioneering initiative of developing paper-based bottles that combine functionality with sustainability. Designed as an alternative to traditional plastic packaging, these bottles offer a transformative solution for industries that are heavily dependent on single-use plastics. This work closely aligns with the UK’s wider sustainability ambitions and the global effort to reduce plastic waste.
Our approach
In response to the challenge set by Pulpex, and building on Pulpex’s interest in using infrared (IR) imaging as a potential quality control approach, Professor Keddie and the team helped develop a fast and robust method for monitoring the bottle coating process during manufacturing. To enable production scale‑up and support broader adoption across beverages, cosmetics, and household products, Pulpex required assurance that the bottles were fully reliable and capable of securely containing liquids over prolonged periods. Leveraging expertise in sustainable materials, thermal imaging, and computer vision, the team partnered closely with Pulpex to explore the feasibility of the idea for quality control processes.
Specifically, the team employed infrared thermography, a technique sensitive to subtle temperature variations, to monitor the drying process from start to finish. They established a proof-of-concept that the infrared thermography was an effective tool for quality control
Next Steps
With the success of the initial project, the collaboration expanded into a bigger project: The team secured a £1 million award through the EPSRC (Engineering and Physical Sciences Research Council) Prosperity Partnerships fund, enabling the continued partnership with Pulpex. The Sustapack research project focuses on developing innovative processes to improve energy efficiency and reduce water use, while ensuring product quality is maintained.
The developments with the University of Surrey in this work continue to bind the advances of effective AI into commercial outcomes for manufacturing assurance. Our SustaPack partnership advances sustainable packaging solutions and accelerates the adoption of fibre-packaging by brand owners, whom in turn meet both their Net-Zero targets and gives consumers sustainable choices, a win for all and the environment.Scott Winston, Managing Director at Pulpex
Prof Joseph Keddie with Pulpex engineer, Josh Nugent.
The project team on site during their visit to Pulpex.
Sustainable Development Goals
The project addresses two key UN SDGs:
- SDG 12 (Responsible Consumption and Production): By enabling more efficient and reliable manufacturing through advanced quality control, the project reduces material waste, energy use, and product rejection, supporting responsible production practices and resource efficiency. These process improvements enable the low‑carbon production of recyclable bottles that, when manufactured at scale, can significantly reduce reliance on petroleum‑based plastics and their associated environmental impacts.
- SDG 13 (Climate Action): The project supports climate action by strengthening quality‑control processes, which in turn reduces rework, material waste, and unnecessary energy use during production. These improvements directly lower the carbon footprint associated with manufacturing and disposal. In addition, the bottles themselves offer a significantly smaller environmental impact, with a carbon footprint around 30% lower than PET and substantially lower than glass.
Contributors
The project team
Professor Joseph Keddie specialises in soft matter physics and leads a research programme linked to sustainability. With more than three decades in academia, Professor Keddie is internationally known for his pioneering contributions to polymer colloids, soft matter physics, and sustainable and living materials. The project drew on his knowledge of materials characterisations.
Dr Isabella Guido is an expert in biological physics. The project benefited from her expertise and research interest in imaging modalities, particularly in relation to biomaterials.
Kushagra Anand supported the project as a research assistant specialising in computer vision. He developed software algorithms for image analysis to support quality‑control processes.
Sanjana Kulappurath, also a research assistant, carried out the experimental work using the IR thermal camera to establish the proof of concept.
Professor Joseph Keddie, Professor of Soft Matter Physics and Fellow at the Institute for Sustainability, School of Mathematics and Physics, University of Surrey; Royal Society Industry Fellow
Dr Isabella Guido, Senior Lecturer in Experimental Biological Physics and Fellow at the Institute for Sustainability, School of Mathematics and Physics, University of Surrey
Kushagra Anand, Research Assistant, University of Surrey
Sanjana Kulappurath, Research Assistant, University of Surrey
Haeyoung Eun, Innovation Lead, Sustainability Innovation Hub, Research, Innovation, and Impact, University of Surrey
Joshua Nugent, Process Engineer, Pulpex Ltd.
Gleb Valitov, Senior Process Engineer, Pulpex Ltd
The Institute for Sustainability facilitates collaborations between scientific experts and organisations. The Institute’s Sustainability Innovation Hub provides expert voices from the Fellows to nurture ideas, encourages collaboration, and supports organisations in the adoption of sustainable practices, products, or services.
Read the latest on the University of Surrey’s UN SDG report here.
Related sustainable development goals
