PaperShell is a Swedish start-up that was born in 2021 from the idea of the two founding partners, Anders Breitholtz and Mathieu Gustafsson, with the core belief that the solution to the climate crisis and a sustainable management of resources is found in nature. 

PaperShell is a composite material based on kraft paper and a biobinder (natural resines), layered and pressed together, to form a thoroughly new material, that carries the name of the company itself: PaperShell. This material is so solid and durable that it can become the shell of a chair, for example, but also components for electronics and automotive, snowboards and much more. Objects we know, but with a completely new impact on the environment. PaperShell dramatically reduces an object's impact on the environment by doing what trees - which PaperShell is derived from - do most naturally: it retains, technically "sequesters", carbon dioxide. The carbon sequestration potential of one kilogram of PaperShell is about 1.5 kilograms of CO2 equivalent. Ultimately PaperShell is a carbon sink, which means that it sequesters more CO2 that it releases during its production process.

The final product is the outcome of a molding process that involves a diverse interplay of parameters such as heat, pressure, and humidity. PaperShell provides the strength and comfort essential to Catifa’s now iconic, tridimensional silhouette. 

The paper used to produce PaperShell is kraft paper. No trees are explicitly cut to produce this, since it is made out of residues from Swedish wood production and timber by-products like sawdust, chips, and branches, which are then processed into the pulp, that is used for PaperShell production. Currently, PaperShell utilizes virgin wood waste for the materials and is investigating the possibility of incorporating recycled paper or alternative sources. Details of water or electric consumption can be found in the PaperShell LCA, downloadable from the PaperShell’s website. 

There are two different dimensions. While FSC ensures sustainable forest management, PaperShell targets CO2 sequestration. One thing does not exclude the other: as a matter of fact, while the raw material (kraft paper) is FSC certified, PaperShell is currently finalizing its certification process.

The shell is crafted without the use of any glue. Each paper sheet is impregnated with water and a natural-based binder, ensuring both structural integrity and environmental friendliness.  

The end-of-life management of the product is key to be regenerative and utilize the full carbon potential of PaperShell. When it comes to the end of life of an object, PaperShell material allows for a sustainable alternative to traditional incineration: the pyrolysis process. This burning process happens in absence of oxygen, hence avoiding the production of CO2 that would happen with a standard incineration process. Thanks to pyrolysis, CO2 is no longer released in the atmosphere, instead it remains densely stored in the structure of the material resulting from pyrolysis, called Biochar. 

Biochar is made up of up to 90% carbon, which locks CO2 effectively, avoiding its release into the atmosphere. Science has proven that for every ton of carbon stored in biochar, about 3.67 tons of CO2 are prevented from entering the atmosphere. Biochar not only sequesters carbon but also improves soil health and reduces greenhouse gas emissions in comparison to standard incineration practices significantly. As a matter of fact, the key contributions of this project to emission mitigation are two: the avoidance of fossil carbon usage for plastic production through material substitution and the capability to sequester CO2 and store it in the ground. On top of it, another important aspect to take into consideration is the avoidance of emissions generated by the traditional production of soil amendment products. 

The partnership with PaperShell is driven by our commitment to emission reduction and the creation of sustainable products. Catifa Carta represents our initial stride in this journey, and we aspire to extend the use of this eco-friendly material across a wide array of both existing and future products.