Optimization of Styrene? Acrylic Latex Barrier Coatings for Oil and Grease Resistant Paper, 2021 TAPPICon Live (21TAPL)

Oil and grease resistance (OGR) is one of the top needs for paper and paperboard packages in the food service industries. Recent regulatory and consumer pressure to remove fluorochemicals in conventional OGR papers has prompted alternative barrier solutions such as polyethylene extrusion coating, wax treatment, and aqueous dispersion coating. Aqueous dispersion coatings provide a cost‐effective and tunable solution and offer better recyclability profiles at low coat weights compared to extrusion coating. A major challenge in developing latex‐based OGR binders is to balance film formation and flexibility with block resistance. Additionally, low oil diffusion through the coating is critical to achieve long‐term OGR barrier. In this paper, we studied the impact of several polymer and formulation parameters on the OGR and block resistance of styrene‐acrylic (SA) latex based OGR coatings. These include the glass transition temperature of SA polymers, the shape and pigment volume concentration of inorganic pigments, and miscibility between the polymer and model oil systems. All factors need to be carefully optimized to achieve a desirable performance balance. These studies led to the development of SA dispersion coatings that offer high OGR barrier, excellent coating flexibility, and low blocking tendency. 

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