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Functional barrier and recyclable packaging materials through microfibrillated cellulose bilayer composite coatings
Aakash Upadhyay1, Lucian Lucia2, Lokendra Pal1
1Department of Forest Biomaterials, North Carolina State University, 431 Dan Allen Dr., Raleigh, NC 27695, USA.
Carbohydrate Polymers
|April 30, 2025
Summary
A new bilayer composite coating (BCC) enhances microfibrillated cellulose (MFC) paper packaging. This sustainable solution improves water resistance and barrier properties while maintaining recyclability and reducing stickies.
Area of Science:
- Materials Science
- Sustainable Packaging
Background:
- Microfibrillated cellulose (MFC) provides excellent gas and oil barrier properties but suffers from poor water resistance.
- Limited water resistance restricts the industrial application of MFC-based materials.
Purpose of the Study:
- To develop an innovative bilayer composite coating (BCC) for paper packaging.
- To enhance water resistance while maintaining the gas/oil barrier and recyclability of MFC.
Main Methods:
- A BCC was designed with a top layer of styrene-butadiene copolymer and nanoclay for hydrophobicity and a bottom MFC layer.
- Scanning electron microscopy (SEM), X-ray photoelectron spectroscopy (XPS), and Time-of-Flight Secondary Ion Mass Spectroscopy (ToF-SIMS) were used for characterization.
- Barrier properties (water vapor transmission rate, air permeability, oil/grease resistance) and recyclability were evaluated.
Main Results:
- The BCC demonstrated a 56% reduction in water vapor transmission rate and a ~630-fold decrease in air permeability.
- Achieved an oil & grease resistance of kit rating 12 and <5% weight gain in hot oil tests.
- Confirmed stable interfaces, prevented layer intermixing, and showed reduced stickies during recycling.
Conclusions:
- The BCC effectively enhances barrier properties and water resistance of MFC-based paper.
- The developed system offers improved recyclability and significant reduction in stickies.
- This strategy enables sustainable packaging solutions with functional barriers for a circular economy.
