Copper-embedded polyvinyl alcohol (PVOH)-based antimicrobial and biodegradable coating for food packaging applications, TAPPI Journal October 2026

 


Application: This study demonstrates the potential of copper-embedded PVOH coatings as a sustainable approach for developing active food packaging materials. These findings provide paper, bioplastic, and bio-based packaging converters with a viable method to design functional barrier coatings that deliver robust antimicrobial defenses without disrupting industrial composting and degradation workflows.

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Author: Ranil Thilanka Peramunu Gamage Don, Kay Cooksey, James Sternberg, and Duncan Darby
Copper-embedded polyvinyl alcohol (PVOH)-based antimicrobial
ABSTRACT: The food packaging industry increasingly seeks multifunctional, bio-based materials that ensure product safety while supporting strict municipal environmental sustainability goals. This research addresses functional limitations in compostable packaging by developing a polyvinyl alcohol (PVOH)-based antimicrobial and biodegradable coating through precise incorporation of active copper ions. Copper ions were incorporated into a 20% solids-content PVOH matrix at target concentrations of 100, 500, and 1,000 ppm, then applied to paper and polylactic acid (PLA) bioplastic substrates at a target coating weight of 6 g/m². Antimicrobial testing against Escherichia coli and Salmonella spp. using a bacterial overlay agar method demonstrated robust, localized microbial inhibition zones that increased with copper concentration. Biodegradability and industrial compostability were assessed under controlled conditions over 49 days in accordance with ASTM D5338 and ASTM D6400. Uncoated butcher paper controls exhibited 71.90% biodegradation, whereas copper-embedded PVOH-coated paper achieved 83.59%, conclusively demonstrating that integrated metallic ions did not hinder or delay natural macromolecular decomposition. Scanning electron microscopy and elemental analysis verified uniform coating distribution and stable copper dispersion across all treated surfaces. Differential scanning calorimetry revealed minor, predictable modifications to polymer crystallization kinetics without altering macrostructural film integrity. Barrier evaluations (ASTM F1249 and ASTM D3985) confirmed a substantial, highly significant reduction in oxygen transmission rates, whereas the reduction in water vapor transmission rates was not statistically significant due to PVOH’s inherently hydrophilic nature. These findings demonstrate that copper-embedded PVOH coatings provide a highly effective, active antimicrobial defense system while remaining completely compatible with commercial, sustainable industrial composting loops.
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