MULTI-FUNCTIONAL BARRIER COATING SYSTEMS CREATED BY MULTI-LAYER CURTAIN COATING, 23TAPPICon

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. Today, there is increasing interest in developing recyclable and more sustainable approaches to producing these types of packages.  

This paper focuses on water-based barrier coatings (WBBC) for OGR, water, MVTR and oxygen barrier performance. The main goal was to create coated systems that can achieve more than one barrier property, using multi-layer curtain coating (MLCC), in a single application step. Curtain coating has emerged as the premier low-impact, contour coating application method for coated paper and paperboard. Significant research work to date and production experience on coated specialty papers and paperboard has focused on conventional coating techniques or single layer curtain coating. Previous work has shown that multi-layer curtain coating has many advantages over these other methods. One advantage is in optimizing coating material cost with the use of functional chemistry in confined layers where performance is balanced within the coating layered structure. This allows simultaneous application of layers of different polymer types in one step to achieve the appropriate performance needs for given barrier application.

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