PAPER making! FROM THE PUBLISHERS OF PAPER TECHNOLOGY INTERNATIONAL ® FROM THE PUBLISHERS OF PAPER TEC Volume 11, Number 1, 2025
Upscaled Multilayer Dispersion Coating Application for Barrier Packaging: PLAX and bioORMOCER® EETU NISSINEN 1 , ADINA ANGHELESCU-HAKALA 1 , ROOSA HÄMÄLÄINEN 1 , PAULIINA KIVINEN 1 , FERDINAND SOMOROWSKY 2 , JANI AVELLAN 3 & RAJESH KOPPOLU 1 The shift from fossil-based packaging materials to more sustainable alternatives is driven by evolving environmental regulations aiming for enhanced recyclability and biodegradability. Dispersion coatings, as opposed to extrusion-based approaches, offer significant advantages by reducing the coat weights, but generally, multiple coating layers are needed to meet functional performance requirements. This study explores the application of upscaled multilayer dispersion coatings comprising polylactic acid-based coating (PLAX) and hybrid nanomaterial lacquer (bioORMOCER®) on commercial base papers for barrier packaging using semi-pilot reverse gravure and industrial-scale rod coaters. One multilayer structure demonstrated a low water vapour transmission rate (WVTR), achieving a WVTR of 12 g/(m 2 ·day) under standard conditions and a 78% reduction of WVTR compared to the substrate under elevated humidity. The other multilayer structure exhibited an excellent oxygen transmission rate (OTR) of 2.3 cc/(m 2 ·day·bar) at dry conditions, which is comparable to conventional high-performance alternatives. Both multilayer coatings enhanced the grease and mineral oil barriers significantly, as heptane vapour transmission rate (HVTR) reductions exceeded 97%. The multilayer coatings demonstrated strong potential for scalable production of sustainable, high-barrier packaging materials. These findings highlight the capability of dispersion coatings to replace traditional fossil- based barriers, advancing the development of environmentally friendly packaging solutions. Contact Details: 1 Sustainable Products and Materials, VTT Technical Research Centre of Finland Ltd., 02044 Espoo, Finland. 2 Fraunhofer-Institut für Silicatforschung ISC, Neunerplatz 2, 97082 Würzburg, Germany. 3 Walki Group Oy, Keilaranta 6, 4th Floor, 02150 Espoo, Finland. Coatings 2025, 15, 214 https://doi.org/10.3390/coatings15020214 Creative Commons Attribution License 4.0
The Paper Industry Technical Association (PITA) is an independent organisation which operates for the general benefit of its members – both individual and corporate – dedicated to promoting and improving the technical and scientific knowledge of those working in the UK pulp and paper industry. Formed in 1960, it serves the Industry, both manufacturers and suppliers, by providing a forum for members to meet and network; it organises visits, conferences and training seminars that cover all aspects of papermaking science. It also publishes the prestigious journal Paper Technology International ® and the PITA Annual Review , both sent free to members, and a range of other technical publications which include conference proceedings and the acclaimed Essential Guide to Aqueous Coating .
Article 9 – Barrier Coating
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