Nexam Chemical enables lightweight materials in bio-based plastics – together with Verdofoam®

Nexam Chemical, a Swedish specialty chemicals company, has achieved a significant breakthrough in sustainable packaging materials through a close collaboration with Verdofoam®, a Netherlands-based biotech company. The partnership has successfully developed a bio-based foam from PLA (polylactic acid) that can replace fossil-based polystyrene in packaging applications — a development with major implications for the e-commerce and food packaging industries.

The Technology Behind the Breakthrough

At the core of this innovation is Nexam Chemical’s proprietary additive technology, which enables the expansion of bio-based plastics like PLA into lightweight foam structures. Previously, creating foam from PLA was a significant technical challenge due to its molecular structure and processing characteristics. Nexam’s additives modify the polymer’s behavior during foaming, allowing it to expand into a cellular structure with the same lightweight and shock-absorbing properties as traditional expanded polystyrene (EPS).

The resulting bio-based foam matches or exceeds the performance of conventional packaging foam in key metrics: it provides excellent cushioning for product protection during transport, maintains its structure under compression, and offers the lightweight characteristics that make it cost-effective for shipping.

Market Impact: Replacing 5.8 Million Tons of EPS

The global volume of expanded polystyrene used in packaging is estimated at approximately 5.8 million tons per year, corresponding to up to 18-30 million tons of CO₂e emissions annually. The ability to replace even a fraction of this volume with bio-based alternatives represents a significant opportunity to reduce fossil dependency and lower the climate impact of packaging.

“This is a clear breakthrough. Being able to create bio-based foam (PLA foam) opens up an entirely new market for us,” said Ronnie Törnqvist, CEO of Nexam Chemical. “We are demonstrating concretely how our technology can help reduce the climate footprint of plastics without compromising performance or functionality.”

Verdofoam’s Role

Hans-Erik Ouwehand, CEO of Verdofoam®, added: “With the help of Nexam Chemicals additives, we have now succeeded in producing a completely bio-based foam with the right structure and properties. It is an important step towards more sustainable packaging solutions.”

Verdofoam brings expertise in bio-based material processing and has been working on sustainable foam technologies for several years. The combination of Nexam’s additive chemistry with Verdofoam’s processing know-how proved essential to achieving the right foam structure and properties.

Applications and Market Segments

The bio-based PLA foam targets multiple high-volume packaging applications:

• E-commerce protective packaging — replacing EPS beads and foam inserts used to protect products during shipping
• Food packaging insulation — temperature-sensitive food delivery and takeaway containers
• Industrial packaging — protective inserts for electronics, medical devices, and fragile goods
• Construction insulation — lightweight insulation panels made from renewable resources

The versatility of the foam allows it to be adapted for different densities, thicknesses, and custom shapes depending on the application requirements.

Sustainability Credentials

The environmental benefits of replacing fossil-based polystyrene with bio-based PLA foam are substantial:

• Carbon footprint reduction — PLA is derived from renewable plant sources (typically corn starch or sugarcane) that absorb CO₂ during growth, significantly reducing net carbon emissions
• End-of-life options — PLA foam can be composted in industrial composting facilities or chemically recycled back to its monomer
• No microplastics — unlike polystyrene, which fragments into persistent microplastics, PLA fully biodegrades under proper conditions
• Renewable sourcing — raw materials come from annually renewable agricultural crops rather than finite petroleum reserves

About Nexam Chemical

Nexam Chemical, headquartered in Lund, Sweden, specializes in additive solutions that improve the properties and extend the lifespan of both recycled and bio-based polymers. The company’s additives are used globally to enhance polymer performance, improve recyclability, and enable new applications for sustainable plastics. The Verdofoam partnership represents a strategic expansion of Nexam’s Lightweight product segment.

About Verdofoam

Verdofoam is a Netherlands-based biotech company focused on developing sustainable foam technologies from bio-based and biodegradable materials. The company’s mission is to replace conventional fossil-based foam products with high-performance alternatives made from renewable resources.

Looking Ahead

As regulatory pressure on single-use plastics intensifies globally and brand owners increasingly commit to sustainable packaging goals, the demand for bio-based foam alternatives is expected to grow significantly. The Nexam Chemical-Verdofoam collaboration positions both companies to capture a meaningful share of this expanding market, offering a proven, scalable solution for replacing fossil-based packaging foam with renewable alternatives.

Source

For more information, visit: Nexam Chemical announcement