5 Must-Have Features in a Barrier Coating for Paper

● Fillers

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Fillers are present in WBBC in the form of a pigment either made from a singular or sometimes multiple sources. The sources include precipitated or ground calcium carbonate, kaolin, or talc.

The fillers present in the pigment form are to make the liquid WBBC runny and help in the easy application of the liquid on the paper. Fillers improve the barrier performance and improve the product economy.

Water-based barrier coating uses a dispersion technique to coat paper. The liquid WBBC is placed over the paper in a skinny layer using blade coating, surface sizing, or curtain coating units on an online board machine. The exact process can also be performed on an offline machine using similar technology. The number of layers applied on the paper directly corresponds to the use of the final product and the number of characteristics the final product needs to have.

The coating process for WBBC differs from that of other paper coating agents as it is not made from plastic. For plastic-based coating solutions, the mix needs to be heated and melted to create the liquid, applied in layers over the paper. Since WBBC is water-based, there is no requirement to heat and melt the material to begin coating.

The process begins with the aqueous solution being applied over the paper in a thin layer. After the coating is complete, the paper is dried, and the water is evaporated off the surface. After the water is evaporated, the paper becomes hydrophobic and able to hold water without any problems.

The technique used in applying WBBC over the paper can significantly impact the finished product. The thickness of the WBBC coating and the drying of the paper can also impact the hydrophobic performance of the coated paper. For example, if WBBC was applied on the paper using a curtain method, it guarantees equal thickness of WBBC coating throughout the paper. On the contrary, if the application was made using the blade coating process, it guarantees a smooth coating over the paper.

• Market Penetration & Availability of Technology

There are recycling plants that can recycle coated paper products without segregating them. However, the number of such plants is few and far between.

This is because even the technology they use to achieve this feat is unavailable to most other plants.

Or in some cases, the technologies are specialized and expensive, which other plants in different parts of the world might not be able to afford.

•  Cost Of Recycling

If the technology is available to recycle coated paper products, then other recycling plants should try to incorporate these technologies in their process, right? Yes, but also no.

The cost of recycling coated paper products increases exponentially when you incorporate new machinery and other processes required to recycle them.

When compared with the value and cost of the raw materials of the coated paper products, it does not justify putting so much investment in recycling the products.

So recycling plants mostly don’t have enough incentive to recycle coated paper products and instead send them to landfills.

There are various uses of water-based barrier coating paper products, but it is mainly used in the food industry for making disposable food packaging.

WBBC is chemically inert and does not influence or impact the taste or smell of the contents in its packaging. These factors make WBBC coating perfect for use in the food industry.

Most of the individual elements used for making WBBC is cleared by the FDA and other governmental authorities for direct food contact. Some of the most common applications of WBBC are mentioned below.

• Disposable paper cups
• Ice cream boxes
• Microwavable food packaging
• Disposable folding box
• Disposable food containers
• Disposable food serving trays
• Food wrappers
• Disposable paper tableware
• Paper pads
• Disposable dairy packaging
• Disposable meat packaging
• Cheese packaging
• Any other food packaging requirement that requires high oil and grease resistance properties

• Plastic-Free 

Today, everyone knows that plastic is terrible for the environment, and everybody wants to make a change and replace plastic with other products, but it is challenging to do.

Even though we are not yet in a position to replace and remove plastic from the environment altogether, the use of WBBC can guarantee that customers can stop plastic use in the food packaging industry at least.

WBBC ensures that the eco-friendly packaging you get with your favorite takeout food is genuinely sustainable and eco-friendly.

Contact us to discuss your requirements of Barrier Coating for Paper. Our experienced sales team can help you identify the options that best suit your needs.

Awareness among recyclers, consumers, and businesses can genuinely help WBBC reach its true potential and bring meaningful change.

It has some of the best benefits in terms of paper coating agents, and it is expected that awareness alone among people can help make it the following standard of paper coating agents.

So, be sure to spread awareness about WBBC to the people you know, and take a moment to ask companies what containers they are using to serve you your favorite food.

With your interest and diligence, companies will be incentivized to make a meaningful change towards eco-friendly and sustainable products, so make sure you use your voice when it matters for a better world tomorrow

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FennoGuard GO is an innovative barrier solution that enables the development  of fully recyclable and repulpable paper and board packaging. The dispersion barrier coating helps to reduce and replace plastics, e.g. Polyethylene (PE) extrusions, used in fiber-based packaging to create needed resistance against oil and grease, moisture, or other substances.

1. Which end uses is FennoGuard GO best suited for?

FennoGuard GO provides excellent oil and grease barrier properties and tailored water vapor resistance, and it is mainly intended for food service board and flexible packaging paper. Typical use case for paper or board that is treated with FennoGuard GO are take away food and fresh bakery products. In these cases, the packaging needs to provide good protection against grease and an optimized vapor resistance. Another example of a demanding end use is packaging for greasy pet food, which requires superior oil and grease barrier and long shelf life.

2. Is the dispersion barrier coating recyclable and compostable?

The compostability and repulpability of fiber-based material that is treated with FennoGuard GO have been proven in a series of tests. The dispersion barrier coating disintegrates in compost and breaks down in the repulping process, which makes the material easy to recycle. However, the base material has an impact on the end-product’s end of life properties, which means that each end-product needs to be tested for compostability and repulpability individually.

It’s good to know that the requirements to claim that a fiber-based packaging is compostable vary between different regions. All schemes study the characteristics of both the packaging and its components and their ability to biodegrade and disintegrate, and take into account the quality of resulting compost. There are on-going efforts in EU to create more clear and uniform guidelines on making compostability claims, and similar action is taken e.g. by the Chinese industry organizations.

3. What is the key benefit of dispersion barrier technology?

Dispersion barrier coating is a sustainable option for providing oil and grease barrier properties, among others, in food packaging as it helps improve the packaging material recyclability and reduces exposure to plastics. It is also a safe alternative to replace the harmful fluorochemistries (perfluoro and polyfluoro alkyl substances, PFAS) that have already been banned in some countries. For the fiber-based packaging material manufacturers, the technology enables the production of higher value products with fewer production steps, e.g. by removing the need for a separate extrusion coating phase. Additional benefits for the paper and board producers include time, material, and production efficiency.

4. Is FennoGuard GO made from renewable raw materials?

The first generation of FennoGuard GO already has a share of renewable bio-based raw materials to replace fossil-based chemistries, which helps further lower the environmental footprint of the food packaging material. We are committed to developing sustainable chemistry solutions and taking steps forward according to our biobased strategy to further reduce exposure to fossil-based raw materials.

5. Does dispersion barrier coating prevent mineral oil migration?

Yes, FennoGuard GO provides proven functional barrier against mineral oil residual migration (MOSH and MOAH). The transfer of harmful mineral oil hydrocarbons from the food contact material to the food is a safety concern especially when recycled fibers are used in production. The latest regulatory update on the topic comes from Germany: a draft for the country’s new Mineral Oil Ordinance by the Federal Ministry for Food and Agriculture (BMEL) proposes that the use of a functional barrier is mandatory in all food contact materials that are manufactured using recycled fibers.

6. Is FennoGuard GO approved for use in food contact?

FennoGuard GO is compliant with key food contact regulations: EU Framework Regulation and the German BfR requirements, which provide the basis for compliance in Europe, FDA §176.170 for North American market, and the Chinese GB standard.

7. What about the runnability of the barrier coating product?

FennoGuard GO has proven runnability on paper and board machines and on converting lines. Convertibility is one of the key features in barrier coating for food packaging. Soft polymers offer flexible coating that gives the needed creasing and folding properties for the packaging, but typically the softer the polymer, the higher the blocking tendency. Our innovative technology overcomes the challenge and FennoGuard GO provides flexible barrier layer while also maintaining low blocking tendency.

8. FennoGuard GO is based on open formula. How is the performance of the tailored barrier coating ensured?

The open formula allows us to help our customers to optimize the barrier performance for the specific packaging end use and tailor the product to meet the needs of their individual paper machines or coating lines. Kemira has excellent capabilities for simulating all the steps from coating color formulation to coating and converting in the laboratory before moving to pilot and mill trials. Barrier performance can also be tested in Kemira laboratory.

9. Is there a preferred application method for dispersion barrier coating?

There is a broad variety of different coating methods in the industry and as each method has its pros and cons, there isn’t just one recommended method for applying dispersion barriers. There are many variables to consider when choosing the coating method, but the best performance can only be reached when a uniform, pinhole-free film is formed on the substrate. Close attention should also be paid to the coating structure, e.g. to the ability to apply thin coating layers. Functional surface barrier can also be applied at the converter utilizing printing units, such as flexography.

Want more information on Barrier Coating for Paper Cups? Feel free to contact us.

10. How to achieve optimized barrier performance in fiber-based packaging?