Every year, millions of cremations are performed worldwide using traditional wooden coffins. This generates significant environmental impacts:
This creates a structural inefficiency within the cremation process.
The coffin produces approximately three times the emissions of the body itself. It is not a passive element, but a dominant variable in the process, this highlights a critical point.
Alberto Recchioni, a Chemist, developed a project in collaboration with the Department of Engineering, Polytechnic University of Marche (Italy).
The innovative coffin was built using bio-based polymer materials, bioPE, derived from renewable sources (sugar cane). Its key characteristic is a negative carbon footprint of −2.12 kg of CO₂. Furthermore, bioPE and wood have important basic chemical differences:
Full test protocols, measurement boundaries, and datasets can be shared under NDA for technical review.
Under the same operating conditions, different effects are produced:
1) The bioPE coffin reduces CO₂
emissions by 90%
| Polluting | bioPE (20 kg) | Wood (70 kg) |
|---|---|---|
| CO₂ (Life Cycle Assessment) – LCA | 19,6 | 200,0 |
| PM (Particulate) | low | higher |
| PAH (Polycyclic Aromatic Hydrocarbons) | low/0 | medium |
| VOC (Volatile Organic Compounds) | low | higher |
| CO | low | low–medium |
| Ashes | ~0 | high |
The new solution contributes to: up to 90% reduction in CO₂ emissions from the coffin, elimination of particulate and harmful volatile compounds, total ash reduction, improved environmental performance of cremation facilities.
This is particularly relevant in urban environments where crematoria operate under strict environmental expectations.
Under controlled conditions, the system enables:
Rapid ignition
Reduction of cremation time by approx. 15–20%
Reduction of gas consumption
Increase in furnace throughput approx. 18%
Reduction of residues and stress on filtration systems
Adhesive-free structure
Absence of metal components; the closing screws are also made of bioPE — they are inserted with a simple pressure
Lightweight (approx. 20 kg); simplifies all operations
Structurally stable
Waterproof, which may improve hygienic management during waiting periods before cremation
These characteristics can simplify management, transportation and storage operations; aspects that can become particularly relevant in contexts where cremation demand is high and temporary storage periods occasionally occur.
The coffin has been engineered with a stackable geometry, enabling a substantial reduction in volume compared to traditional wooden coffins. This characteristic allows for a more efficient use of storage space and transportation capacity, contributing to improved logistics performance and reduced operational complexity across the supply chain.
The impact of this design can be summarized as follows:
| Parameter | Wooden Coffin | bioPE Coffin |
|---|---|---|
| Structural design | Rigid | Stackable (nestable) |
| Space required (storage & transport) | 100% baseline | Up to –70% space required |
| Logistics efficiency | Limited | Significantly improved |
| Supply chain optimization | Constrained | Enhanced |
| Operational handling | Standard | Simplified |
Estimated reduction based on stackable design compared to standard wooden coffin geometry.
The manufacturing process is based on:
High-efficiency injection moulding
Scalable industrial processes
Consistent quality output
High-volume production capability
Bio-based polymers are already industrially available and compatible with existing manufacturing infrastructure.
The technological concept is protected by an international patent portfolio (PCT) covering:
Patent protection extends to both: the use of bio-based materials, and the functional configuration specifically optimised for cremation, making the solution difficult to replicate or bypass.
The objective of this protection is not only to safeguard the intellectual property associated with the concept, but also to support potential industrial development and responsible technological collaboration in different international contexts.
In this sense, the patented concept may provide a structured foundation for further technical evaluation and possible cooperative exploration with organizations involved in funeral services and cremation technologies.
Alberto Recchioni, Chemist, is Inventor & Patent Holder of the project.
This project is not simply a replacement for an existing product, it is a goal.
“The project using bioPE instead of wood to construct a cremation coffin offers a unique solution. The timing of introducing this solution to the market is urgent, given climate change and expected future legislative changes.”
This coffin is unique because it is completely different from anything else on the market, because it requires no new structural adaptations, and because it is able to meet the needs and desires of all funeral professionals.
A company that wants to be perceived as responsible and attentive to sustainability will find in this innovative coffin a powerful tool to build a strong public image.
Participating in the sustainable evolution of crematory practices further strengthens this positioning.
This technology represents:
An opportunity to improve operational efficiency
A measurable reduction in energy-related costs
A positioning advantage in sustainability
Potential differentiation in a consolidating market
In the context of long-term ESG responsibility, operational efficiency and governance stability, this innovation represents a structurally relevant opportunity to contribute to the evolution of cremation standards in Europe.
Beyond its measurable environmental and operational benefits, the strategic value of this solution lies in its capacity to redefine how cremation efficiency and emission accountability are integrated within a vertically structured funeral group.
In markets characterised by structural stability and limited systemic innovation, early positioning around measurable and scalable technological improvements can shape long-term competitive leadership.
The figures provided are based on controlled testing conducted in collaboration with the Department of Engineering of “Materia e Ambiente (SIMAU) Università Politecnica delle Marche” (Italy).
Full test protocols, measurement boundaries, and datasets can be shared under NDA for technical review.
The design concept has been developed to reduce unnecessary mass and structural complexity compared with traditional wooden coffins.
The overall weight of the coffin structure is approximately 20 kg, which is significantly lower than many traditional coffin designs.
Because the material mass is lower and the ignition phase may occur more rapidly, but without creating significant thermal stress for the cremation chamber (different energy)*.
In practice, the concept may contribute to a more efficient use of combustion energy rather than altering the normal operating parameters of cremation furnaces.
As with any technical innovation, verification through controlled operational testing would be recommended.
A biopolymer coffin burns as soon as it is placed in the oven, since the ignition temperature of biopolymers such as bioPE and bioPP is between (330/350°C).
the energy contribution is similar (total energy comparable to wood)
the coffin accounts for a smaller fraction of the total energy balance; the body dominates the process
the total cremation time is dominated by the body
the bioPE coffin burns faster than the wooden one
the combustion time of the coffin alone is reduced
It is not a futuristic technology, it is based on technologies and materials already industrially produced.
Braskem, the manufacturer of bioPE, guarantees delivery in short time and for any quantity requested.
The concept has been developed with particular attention to industrial feasibility.
From a technical perspective, the concept has been conceived with industrial manufacturability as a central design principle.
The manufacturing process is based on high-efficiency injection molding (16 coffin houar), enabling standardized, high-volume output with consistent quality.
Bio-based polyolefin materials such as bio-polyethylene maintain mechanical properties comparable to conventional polymers and are already produced on an industrial scale for many applications.
From a manufacturing perspective, the coffin structure has been designed with several characteristics that support industrial production:
simplified geometry
absence of metal components
absence of adhesive bonding
modular
The concept therefore does not rely on experimental materials or unconventional manufacturing processes, but rather on the adaptation of existing industrial capabilities to a new application.
Naturally, the transition from concept design to large-scale production would require further engineering development, prototyping and validation under operational conditions.
We can propose a company-wide implementation plan (pilot project → regional implementation → network scalability) and define contingency measures (dual sourcing of raw materials, safety stock policies and appropriate quality assurance protocols).
The structural characteristics of the concept may provide several logistical advantages.
The coffin is designed to be:
lightweight (approximately 20 kg)
structurally stable
stackable for efficient storage
waterproof, which may improve hygienic management during waiting periods before cremation
These characteristics may simplify handling and transport operations while maintaining appropriate dignity for funeral presentation.
Such operational aspects may become particularly relevant in contexts where cremation demand is high and temporary storage periods occasionally occur.
No. The solution is designed for integration without infrastructure retrofitting. Any operational changes would be procedural (e.g., handling and staging) rather than equipment-related, and can be validated during a pilot.
The solution is intended to create value through measurable operational efficiency and energy impact, not only through unit cost comparison. We suggest evaluating total cost impact per cremation, including gas consumption, cycle time, throughput consistency, and maintenance stress. We can model an specific business case using your baseline assumptions under confidentiality.
The concept has been developed with careful consideration of both operational and cultural aspects of funeral services.
The external design maintains a dignified and simple appearance consistent with contemporary funeral aesthetics.
In many regions, families are increasingly aware of environmental considerations and may appreciate solutions that reduce the environmental impact of cremation while maintaining ceremonial dignity.
The final acceptance of such a concept would naturally depend on cultural perception, presentation and the way in which the concept is integrated within existing funeral practices.
The solution is protected under an international patent portfolio (PCT) covering the U.S., EU, Japan, and China, addressing both the biobased material approach and the cremation-optimized functional configuration. We can provide patent documentation and outline licensing structures that support strategic protection.
We can support a pilot quickly once scope is agreed: define site selection criteria, provide sample volumes, align on measurement plan, and support training/handling procedures.
Timing details will be jointly defined based on operational calendars and specific compliance requirements.
Director – Department of Engineering
Università Politecnica delle Marche – Ancona (Italy)