Production of polyhydroxyalkanoates (PHA)-based renewable packaging materials using photonic energy:  A bench and pilot-scale study, TAPPI Journal October 2018

ABSTRACT: This work describes the utilization of a new photonic heat treatment technology in combination with polyhydroxyalkanoates (PHA) materials for the development of biofriendly packaging and coated substrate materials. This technology advances the use of aqueous PHA coatings as a replacement for less environmentally friendly extruded plastic and fluorotreated packaging papers and boards. The new technology utilizes short burst photonic energy to heat PHA latex coatings. Utilizing a rapid pulse of photonic energy enables PHA particles to melt and form a film within milliseconds, as compared to conventional equilibrium drying that takes several minutes. Coatings were applied to commercially produced papers in order to validate the combined use of photonic treatment technology with PHA materials for commercial applications. Photonic treatment for both bench-top and roll-to-roll pilot-scale studies resulted in kit values of 12, and 2 min Cobb values of <2 g/m². Repulpability studies showed the material to be completely repulpable, having 100% accepts after screening. The results demonstrate that the photonic treatment of PHA polymers could be used in current commercial settings to produce environmentally friendly packaging and coated products.

Application: By combining aqueous based PHA coating with photonic drying technology, it is now possible to implement PHA in commercial applications pertaining to environmentally friendly barrier coatings for the manufacture of functional paper and paperboard products, specifically for moisture vapor, moisture, and grease resistance. It presents an alternative to conventional non-renewable extruded polyethylene, petroleum-based latex coatings, and fluorochemical and chromium-containing coatings. Industry impacts for the introduction of this technology include: introduction of green chemistry formulations into coating processes, reduction of plastic waste in the recycle stream, increased utilization of renewable and sustainable product lines, and decreased carbon footprints.

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