It may seem unusual but the idea for lifelia coffins first emerged in the print sector. Robert Farfort, the founder and CEO of successful large-scale print production house, came up with the concept after learning about the significant environmental damage and health risks of cremations in the UK caused by coffins that had been manufactured in the same way for decades.

Traditionally made from MDF and particle board held together with toxic glues, and featuring plastic handles, these coffins release dangerous gases when burnt, including carcinogenic formaldehyde from the glues, resins, and lacquers used. And each coffin contributes to the estimated felling of more than 18 million trees every year.

In addition, personalised coffins that feature graphics or text specific to the deceased, are often painted or printed using inks that contribute to harmful greenhouse gases.

As an innovator of green technologies and processes in the print sector, Robert felt compelled to create an alternative.

“The project to create a truly environmentally friendly and safe coffin started more than three years ago when I learnt about the damage being done to the environment by coffins used in cremations,” he said.

“I soon discovered that despite growing demand for environmentally friendly coffins from bereaved families and society at large, there wasn’t an option available that offered the advantages that funeral directors were looking for, such as the ability to be custom made to any size quickly at a lower price point. Many funeral directors I spoke to were also concerned about the impact on the environment and on health caused by cremating coffins made of MDF or particle board, and knew that although the industry isn’t that regulated now, it’s only a matter of time before green legislation is bought in.”

Pro-Origin Board

Research and development led to Robert and his team create Pro-Origin Board, material that looks the same as traditional wood but is made from sustainably sourced wood fibres from Forest Stewardship Council (FSC) approved plantations. Importantly its production doesn’t include the use of any glues, resins, or lacquers that release gases such as nitrous oxide into the atmosphere during the cremation process.

“Pro-Origin Board is a revolutionary material that is biodegradable, recyclable, and lightweight yet is incredibly strong and the material doesn’t harm the environment in any way when it is burnt,” Robert commented. And because a coffin made with it is watertight, funeral directors don’t need to buy a liner that every other coffin uses. This is also better for the environment, whilst also saving them money.”

But not content to simply create a new material for the construction of environmentally friendly coffins, the lifelia team then sourced a range of ‘green’ inks that could safely be used to personalise their coffins in the ways bereaved families wanted.

And they developed a production process that introduced the unique concept of ‘Parametric Sizing’ – the ability for any coffin to be produced quickly and easily in any size requested by funeral directors.

“The innovations we have developed mean that we can cost effectively produce anything from one to thousands of high quality environmentally sound and safe coffins at the touch of a button, and each one can be a different size and personally customised. But we know that to truly help protect the environment and reduce health issues we also needed to offset the carbon used in the production process and strive towards being a net zero emissions manufacturer. So that is exactly what we did and continue to focus on as we launch lifelia coffins into the market,” said Robert.

‍But lifelia is not the first time that he has disrupted an industry with environmental innovations. His company was the first to develop and launch a range of 100% recyclable cardboard exhibition stands that use water based adhesives and inks, are compostable, and solvent free.

For Robert, protecting the planet is about more than just making good economic sense.

“Many sectors still have a long way to go to ensure they are not contributing to the climate crisis we face today, but every one of them has a responsibility to make the changes needed to safeguard the environment for everyone. The end-of-life sector is no different and I hope the coffins we have created and the processes we have introduced will help make a substantial positive difference now and in the future.”