MULTI-FUNCTIONAL BARRIER COATING SYSTEMS CREATED BY MULTI-LAYER CURTAIN COATING, 2021 TAPPICon Live (21TAPL)

Functional coatings are applied to paper and paperboard substrates to provide resistance, or a barrier, against media such as oil and grease (OGR), water, water vapor (MVTR) and oxygen, for applications such as food packaging, food service and other non-food packaging.  Typical functional barrier coatings can be created by applying a solid coating or extruded film, a solvent based-coating or a water-based coating to the paper substrate using various means of coating applicators.  This paper focuses on water-based barrier coatings (WBBC) for OGR, water, MVTR and oxygen barrier.  The main goal was to create coated systems that can achieve more than one barrier property, using multi-layer curtain coating (MLCC).  Curtain coating has emerged as the premier low-impact application method for coated paper and paperboard.  Significant research work to date and production experience on specialty papers and paperboard has focused on conventional coating techniques or single layer curtain coating.  However, multi-layer curtain coating has many advantages over these other methods.  One advantage of lower material cost is through the use of functional chemistry in confined layers where performance is optimized within the coating structure. 

This allows applying simultaneously layers of different polymer types to achieve the appropriate performance.  The MLCC also allows the application of such coatings in one coating operation step minimizing capital investment and machine foot print.  Another advantage is the ability to generate thin “contour” layers which are more economically feasible than what is applicable for common coating technologies where excess material is applied in some regions in order to get the minimum coverage in the areas where the basesheet is thinner.  The latter is even more critical when basesheet roughness is not well controlled or is inherent to the substrate available.

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