Development Story of the Bio High-Barrier Foil Liner

Ten years of research, countless setbacks – and a clear vision: with the new Bio High-Barrier Foil Liner, Clesana has reached a technological milestone. From concept to market launch, this development proves that hygiene, sustainability and innovation do not have to be mutually exclusive.

 

 

The development of successful technologies rarely begins with a finished product – but with an idea that is consistently pursued over many years. This was also the case at Clesana. As early as 2009, the founding team was convinced that traditional sanitary technology – especially in the mobile sector – needed to be completely rethought. Their vision was of a hygienic, waterless system that conserves resources and is environmentally sustainable.

A key element of this idea was the ffoil liner from the very beginning. While it may seem simple in practice – a sealed bag that contains waste – its technical implementation posed a major challenge. The high-barrier foil needed to provide effective protection and be reliably impermeable to both moisture and oxygen.

In the early years, the focus was entirely on one thing: safety. Clesana’s guiding principle was that a waterless toilet system would only be accepted if the hygienic sealing functioned with absolute reliability. Classic, petrochemical-based materials were used – not out of disregard for environmental concerns, but due to technological necessity. At the time, bio-based materials simply did not offer the required performance and lacked the stability and barrier properties needed to effectively block odors, germs and moisture.

 

 

Daniel Beller, CEO of Clesana AG, explains: “We started with the core idea of making hygiene possible without access to water. But when we entered the caravaning market, a new ambition emerged – to become even more sustainable.” The next step, therefore, was to develop a more sustainable version of the high-barrier foil liner. Starting in 2018, Clesana launched a systematic search for sustainable alternatives.

The challenge: A bio-based foil had to match the barrier performance of its petrochemical predecessors – while maintaining compatibility with existing machinery, storage stability and temperature resistance.

Together with partners from research and industry, a wide range of bio-based substances were tested – including lignin, talc, wax, and natural resin. The results? Often disappointing. Some materials couldn’t be sealed properly, others lost their barrier properties when exposed to moisture, or failed due to processing speed limitations. Yet despite all the setbacks, the goal remained unchanged – driven by the conviction that hygiene and sustainability must not be mutually exclusive.

 

The decisive breakthrough came when a material combination was found that met all the necessary criteria: bio-based, recyclable, sealable, with a high barrier – and, of course, fully compatible with Clesana’s sealing technology.

In close collaboration with compounders, equipment manufacturers, and the in-house development team, an entirely new formulation was created. At the same time, the sealing and bonding technology was further refined to seamlessly integrate the new foil into the existing Clesana system.

At the beginning of the year, the bio high-barrier foil liner underwent a series of rigorous tests. First, the oxygen and moisture barrier properties were tested by the Fraunhofer Institute – with results showing slightly better performance than the previous conventional high-barrier foil liner. This was followed by successful DIN certification by TÜV Rheinland. As a result, series production will begin in mid-2025 – initially for the caravaning industry, and later for medical applications, mobile care, and use in disaster relief and development aid contexts.

What remains unchanged is the original vision: a hygienic and sustainable disposal solution that empowers people around the world – independent of water connections, sewage systems and existing infrastructure. The new liner marks another significant step on the path to making that vision a reality.

 

Shop Now: Bio High-Barrier Foil Liner

 

 

“Now we have a foil that is bio-based and reliably delivers high barrier performance. That was the goal – and we’ve achieved it. It’s not just about innovation, it’s also about responsibility.”

– Daniel Beller, CEO of Clesana AG

The new bio high-barrier foil liner is more than just a product – it is the result of ten years of research, setbacks, learning and progress. At the same time, it stands as proof of what is possible when a company believes in its vision and commits fully to achieving its goals.

 

More Information about the Bio High-Barrier Foil Liner

 

Clesana is an innovative company from Switzerland that is redefining mobile sanitation solutions. With the Clesana C1, the company has developed a sealing toilet that uses thermal pressure sealing to deliver the highest levels of hygiene, comfort, and safety. Excretions, hygiene products and similar materials are securely sealed in a high-barrier foil and can be easily disposed of with regular household waste. This eliminates the need for supply and disposal stations, enabling true independence.

The Clesana system has its origins in the medical field, originally designed to protect Swiss waters from contamination by pharmaceutical residues, hormones, and other chemicals. As a result, the Clesana C1 holds itself to the highest standards of hygiene.

The renowned Fraunhofer Institute has confirmed that Clesana bags perform best by far in terms of odor barrier and leak protection. The high-performance barrier ensures that excretions and other contents are securely enclosed, preventing any contact with the contents for users and all those involved in the disposal process.

The Clesana C1 operates without water, conserving this valuable resource. It also completely avoids the use of harmful chemical additives. A bio-based high-barrier liner made from biomass and recycled materials is now available. Additionally, the C1 is manufactured entirely in Switzerland, keeping its carbon footprint to an absolute minimum.

 

Press Contact Clesana AG
POC: Tino V. Göbel / presse@clesana.com