5 Reasons Why Your Business Needs water based barrier coatings？

Global Packaging Industry's Green Transformation

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As global environmental awareness rises and plastic reduction policies advance worldwide, the packaging industry is undergoing a significant transformation. Traditional plastic packaging is gradually being replaced by eco-friendly alternatives, with water-based barrier coating combined with paper packaging emerging as one of the most promising sustainable solutions. According to Allied Market Research, the water-based coating market was valued at $68.7 billion in and is estimated to reach $110.9 billion by , growing at a CAGR of 5.1% from to .

Growth of Water-based Coatings on Paper for Packaging

Going back to the fundamentals: The purpose of barrier coatings and packaging is to protect the goods inside, preventing unwanted substances from leaking out or getting in. Substances such as oil, grease, water, and moisture are common substances to block. Furthermore, it would be a big plus if the barrier coating and packaging could offer attributes such as heat sealing ability, abrasion resistance, heat resistance, and over-printability. Without delivering the above functionalities, we can talk all day about sustainability, recyclability, or reducing carbon footprints, but ultimately, the solution will never go mainstream.

Water-based coatings on paper are becoming increasingly popular, driven by regulatory requirements. In addition to reducing environmental impact, advancements in water-based coatings now provide mechanical strength and shelf life that are acceptable to both consumers and packaging providers. Furthermore, the widespread adoption of such water-based coatings on paper facilitates recycling, promotes environmental friendliness, and contributes to a smaller carbon footprint.

The Key to a Successful Water-based Coating on Paper Operation

There are 4 factors for a successful water-based coating on paper operation:

1.The flexibility to switch between different coating methods due to the continuous introduction of diverse water-based coatings in the market.

2.The ability to provide a precise and uniform coating layer.

3.The ability to integrate multiple coating layers.

4.The capability to provide an optimal drying method for the different coating solutions. 

If we dive deeper, drying involves creating a customized drying temperature curve through stable output control at each drying stage while maintaining high energy efficiency. 

Introducing the Hybrid-X from KYMC. Hybrid-X is a multi-layer coating system specifically optimized for water-based barrier coating applications.

Hybrid-X offers unique advantages in water-based coating applications with its ability to precisely control coating parameters, ensuring uniform coating thickness with consistent coating quality. Hybrid-X allows you to conduct quick coating material changeovers and is flexible in parameter adjustment. The machine could also equip real-time coating inspection and intelligent process control, providing complete quality tracking. On top of the advanced water-based coating technology, you will also receive professional technical support from the KYMC team.

Take action now for a more sustainable business

At this pivotal moment in the packaging industry's journey toward sustainability, Hybrid-X offers the most comprehensive water-based coating solutions. Through innovative technology and flexible customization services, KYMC helps clients achieve their plastic reduction goals and contribute to a greener future for the packaging industry.

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Contact us to discuss your requirements of water based barrier coatings. Our experienced sales team can help you identify the options that best suit your needs.

As the term “barrier” implies, these packaging papers have a coating that guarantees a physical barrier against moisture and grease, for example. These barriers have traditionally been achieved using plastics, but now barrier papers provide a renewable alternative for many end-uses, while offering protection for the product inside. Achieving these features while ensuring that the paper can still be recycled requires extensive R&D work and a high level of expertise in paper making.

They protect the product inside and out

Barrier papers are strong enough to withstand the demands of transporting the product from the production facility all the way to the consumer.

The water vapor barrier offered by barrier papers is impressive. The barrier layer helps to protect dry foods like flour by keeping moisture out of the packaging, while also keeping foods like toast fresh for longer by preventing moisture from leaving. For baked bread, the barrier layer even allows warm steam to escape, preventing a crisp loaf from going soggy before you eat it.

Another example of the barrier layer is that it prevents grease from penetrating the package. In muesli for example, nuts and dried fruit contain fats that could result in the paper looking and feeling greasy – the barrier layer keeps it from doing that.

They can be used as a co-creation base

Barrier papers start with the  base functionalities mentioned above, but it’s possible to work with converters to further process the paper in order to develop packaging that has additional barriers to suit the needs of different end-uses.

This system of co-creation with brands and converters is needed to find the best packaging for different end-uses, while helping brand owners meet their target of introducing more sustainable packaging.

For example, packaging for muesli that contains nuts or dried berries could use UPM AsendoTM as a base, with more barrier layers added by the converter to improve its grease resistance.

They are recyclable

Fibre-based barrier papers offer one solution to the problem of plastic waste in the food packaging industry. In fact, one benefit of paper as a packaging material is that it can be recycled in existing recycling streams. To achieve barrier properties without compromising recyclability, a lot of development work and expertise in paper making is needed.

According to Cepi, over 70% of paper was recycled in , keeping fibres in the loop longer and extending the benefits of their renewable origin. If a package does not make it into the recycling bin, some barrier papers like UPM Asendo are biodegradable, acting as a “fail safe” in case they would end up in nature

Because barrier papers not only protect the product but also act as a print surface, they often eliminate the need for secondary and tertiary packaging for food items, further reducing waste.

For example, most frozen pizzas are currently packaged in a plastic film that is inside a cardboard box. If 70% of all frozen pizzas sold worldwide made the transition to barrier paper packaging, our experts estimate we could free the world from over 2 billion plastic packages in just one year.

They’re designed for shelf-appeal

Barrier papers offer brands the possibility to develop the best look and feel for their particular needs. Papers with two-sided coating like UPM AsendoTM Pro provide a printing surface that allows for sharp lettering, vivid colours and good visuality.

Additionally, barrier papers that are only coated on the inside presenting a surface that looks more natural and has an earthy feel.

They’re safe for direct food contact

UPM barrier papers comply with the most demanding requirements for direct food contact such as BfR and FDA

Barrier papers can also be used as a liner material when using recycled fibres in outer layer of packaging, for example in fruit trays. When newspapers and magazines are recycled traces of inks containing mineral oils may be present in those recycled fibres, meaning they can pose a health risk if they come in direct contact with food. UPM Specialty  Papers has created two innovative technical solutions for preventing mineral oil migration: barrier papers UPM Asendo™ Pro and UPM Asendo™.

Text: Lara McCoy

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