Upscaled Multilayer Dispersion Coating Application for Barrier Packaging: PLAX and bioORMOCER®

Eetu Nissinen; Adina Anghelescu-Hakala; Roosa Hämäläinen; Pauliina Kivinen; Ferdinand Somorowsky; Jani Avellan; Rajesh Koppolu

doi:10.3390/coatings15020214

Upscaled Multilayer Dispersion Coating Application for Barrier Packaging: PLAX and bioORMOCER®

Eetu Nissinen^*, Adina Anghelescu-Hakala, Roosa Hämäläinen, Pauliina Kivinen, Ferdinand Somorowsky, Jani Avellan, Rajesh Koppolu

^*Corresponding author for this work

Research output: Contribution to journal › Article › Scientific › peer-review

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Abstract

The shift from fossil-based packaging materials to more sustainable alternatives is driven by evolving environmental regulations aiming for enhanced recyclability and biodegradability. Dispersion coatings, as opposed to extrusion-based approaches, offer significant advantages by reducing the coat weights, but generally, multiple coating layers are needed to meet functional performance requirements. This study explores the application of upscaled multilayer dispersion coatings comprising polylactic acid-based coating (PLAX) and hybrid nanomaterial lacquer (bioORMOCER®) on commercial base papers for barrier packaging using semi-pilot reverse gravure and industrial-scale rod coaters. One multilayer structure demonstrated a low water vapour transmission rate (WVTR), achieving a WVTR of 12 g/(m2·day) under standard conditions and a 78% reduction of WVTR compared to the substrate under elevated humidity. The other multilayer structure exhibited an excellent oxygen transmission rate (OTR) of 2.3 cc/(m2·day·bar) at dry conditions, which is comparable to conventional high-performance alternatives. Both multilayer coatings enhanced the grease and mineral oil barriers significantly, as heptane vapour transmission rate (HVTR) reductions exceeded 97%. The multilayer coatings demonstrated strong potential for scalable production of sustainable, high-barrier packaging materials. These findings highlight the capability of dispersion coatings to replace traditional fossil-based barriers, advancing the development of environmentally friendly packaging solutions.

Original language	English
Article number	214
Journal	Coatings
Volume	12
Issue number	2
DOIs	https://doi.org/10.3390/coatings15020214
Publication status	Published - 11 Feb 2025
MoE publication type	A1 Journal article-refereed

Funding

This study was funded by the European Union’s Horizon 2020 research and innovation programme under grant agreement N°952972.

Keywords

barrier coating
multilayer coatings
nanomaterial
packaging
polylactic acid

UN SDGs

This output contributes to the following UN Sustainable Development Goals (SDGs)

Access to Document

10.3390/coatings15020214Licence: CC BY

coatings15020214Final published version, 2.77 MBLicence: CC BY

Cite this

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title = "Upscaled Multilayer Dispersion Coating Application for Barrier Packaging: PLAX and bioORMOCER{\textregistered}",

abstract = "The shift from fossil-based packaging materials to more sustainable alternatives is driven by evolving environmental regulations aiming for enhanced recyclability and biodegradability. Dispersion coatings, as opposed to extrusion-based approaches, offer significant advantages by reducing the coat weights, but generally, multiple coating layers are needed to meet functional performance requirements. This study explores the application of upscaled multilayer dispersion coatings comprising polylactic acid-based coating (PLAX) and hybrid nanomaterial lacquer (bioORMOCER{\textregistered}) on commercial base papers for barrier packaging using semi-pilot reverse gravure and industrial-scale rod coaters. One multilayer structure demonstrated a low water vapour transmission rate (WVTR), achieving a WVTR of 12 g/(m2·day) under standard conditions and a 78\% reduction of WVTR compared to the substrate under elevated humidity. The other multilayer structure exhibited an excellent oxygen transmission rate (OTR) of 2.3 cc/(m2·day·bar) at dry conditions, which is comparable to conventional high-performance alternatives. Both multilayer coatings enhanced the grease and mineral oil barriers significantly, as heptane vapour transmission rate (HVTR) reductions exceeded 97\%. The multilayer coatings demonstrated strong potential for scalable production of sustainable, high-barrier packaging materials. These findings highlight the capability of dispersion coatings to replace traditional fossil-based barriers, advancing the development of environmentally friendly packaging solutions.",

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language = "English",

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AU - Nissinen, Eetu

AU - Anghelescu-Hakala, Adina

AU - Hämäläinen, Roosa

AU - Kivinen, Pauliina

AU - Somorowsky, Ferdinand

AU - Avellan, Jani

AU - Koppolu, Rajesh

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AB - The shift from fossil-based packaging materials to more sustainable alternatives is driven by evolving environmental regulations aiming for enhanced recyclability and biodegradability. Dispersion coatings, as opposed to extrusion-based approaches, offer significant advantages by reducing the coat weights, but generally, multiple coating layers are needed to meet functional performance requirements. This study explores the application of upscaled multilayer dispersion coatings comprising polylactic acid-based coating (PLAX) and hybrid nanomaterial lacquer (bioORMOCER®) on commercial base papers for barrier packaging using semi-pilot reverse gravure and industrial-scale rod coaters. One multilayer structure demonstrated a low water vapour transmission rate (WVTR), achieving a WVTR of 12 g/(m2·day) under standard conditions and a 78% reduction of WVTR compared to the substrate under elevated humidity. The other multilayer structure exhibited an excellent oxygen transmission rate (OTR) of 2.3 cc/(m2·day·bar) at dry conditions, which is comparable to conventional high-performance alternatives. Both multilayer coatings enhanced the grease and mineral oil barriers significantly, as heptane vapour transmission rate (HVTR) reductions exceeded 97%. The multilayer coatings demonstrated strong potential for scalable production of sustainable, high-barrier packaging materials. These findings highlight the capability of dispersion coatings to replace traditional fossil-based barriers, advancing the development of environmentally friendly packaging solutions.

KW - barrier coating

KW - multilayer coatings

KW - nanomaterial

KW - packaging

KW - polylactic acid

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Upscaled Multilayer Dispersion Coating Application for Barrier Packaging: PLAX and bioORMOCER®

Abstract

Funding

Keywords

UN SDGs

Access to Document

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INN-PRESSME: open INNovation ecosystem for sustainable Plant-based nano-enabled biomateRials deploymEnt for packaging, tranSport and conSuMEr goods

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Upscaled Multilayer Dispersion Coating Application for Barrier Packaging: PLAX and bioORMOCER®

Abstract

Funding

Keywords

UN SDGs

Access to Document

Other files and links

Fingerprint

Projects

INN-PRESSME: open INNovation ecosystem for sustainable Plant-based nano-enabled biomateRials deploymEnt for packaging, tranSport and conSuMEr goods

Cite this