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Sustainable coating solutions for Paper & Paper board

Shailesh Nema – Vice President & Managing Director

IIPTA 55th Annual General Meeting & Seminar– Ahmedabad, 8th & 9th March 19

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What is Sustainable Packaging?

• Beneficial, safe & healthy for individuals and communities throughout its life cycle

• Sourced, manufactured, transported, and recycled using renewable energy

• Optimizes the use of renewable or recycled source materials

• Manufactured using clean production technologies and best practices

• Physically designed to optimize materials and energy

• Meets market criteria for performance and cost

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• Legislation & regulationsPushing for innovative eco-friendly & Sustainable packaging

• Consumer awarenessMillennials, purchasing power is rapidly on the rise and are especially interested in choosing socially and environmentally responsible brands

• Conscious capitalismBusinesses committing to be environmentally conscious

Growing demand for Sustainability

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Benefits

• Recyclable• Biodegradable• Shelf appeal

Paper in packaging – Benefits & Limitations

Limitations

• Natural source• Strength & Non Flexible• Poor- Barrier properties• Once barrier properties are improved, Paper can be a good alternative to plastic.

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• Water Based coatings

• Green solutions, Eco- Friendly

• Improves and enhances barrier properties

• FDA approved

• APEO free

Recyclable solutions for Paper & Paperboard

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Benefits of water based coatings

Barrier properties

• Coatings can improve paper's barrier properties which is a crucial step in increasing its viability as a packaging material

• Barrier coatings can help in achieving the OTR & MVTR values required for dry food products

• MVTR – 10 gms/m2/24 hr

• OTR – 70 cc/m2/24 hr

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Applications - Barrier properties

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MVTR < 10

OTR < 80

MVTR < 10

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Benefits of water based coatings

Oil & Grease Resistance

• Coatings enhance oil & grease resistance in Paper

• Acts as freshness barriers

• Keeps perishables safer over a longer period of time

• Recyclable & Repulpable

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Application- Oil & Grease Resistance

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3M KIT >10 3M KIT >9 3M KIT >10

3M KIT > 8 3M KIT > 8

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Benefits of water based coatings

Water Repellent

• Environmentally friendly

• Imparts water repellant property to paper

• Heat Sealable

• Recyclable & Repulpable

• FDA complaint

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Application - Water repellent

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COBB < 10 COBB < 10

COBB < 10

COBB < 10

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Water based coatings for Aesthetics

• Coatings can improve the Aesthetics of the

paper/final product

• Haptic coatings can enhance the look and feel of

the product

• Shelf appeal

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Brand Backlash

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March 22, 2017 March 20, 2018

• Starbucks is teaming up with Closed Loop

Partners‘ Center for the Circular Economy to

create the NextGen Cup Challenge.

• The challenge will award grants to

entrepreneurs working on ideas that could lead

to the development of more sustainable cups.

• The challenge represents a the first step toward

keeping cups out of landfills and making them

recyclable or compostable. Whatever solutions

come out of the challenge will be open source,

to encourage other coffee companies to join in.

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Coatings for PE replacement in paper cups

• Eco-friendly alternative to plastic cups

• Recyclable, Re-pulpable

• Food Grade, FDA Certified for direct food contact

• 2 stage coating process, with coat weight as low as 4gsm

• Energy efficient, seals at lower temperatures than PE

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Biodegradable solution

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Weight Loss (Soil Burial) Test Results

Date of Start: 15-Nov-2018Date of Report: 28-Feb-2019

No. of Days: 105Test Standard Followed: Party’s Request

Material Initial Wt., gm Final Wt., gm Weight Loss (%)

Coated Paper 13.88 1.85 86.67

Biodegradability Test Results

Date of Start: 13-Feb-2019

Date of Report: 28-Feb-2019

No. of Days: 15

Test Method Followed: IS/ISO 14855-1

Material Biodegradation (%)

Coated Paper 29.88

Source: Indian Institute of Packaging

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Coatings for PE replacement in paper cups

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Coating details

Base coat

Base coat weight 2 gsm / dry

Solid Content 53%

Recommended coating method Gravure, Rod coater

Recommended drying condition Hot Air Dryer

Top coat

Top coat coating weight 2 gsm / dry

Solid Content 53%

Suggested coating method Gravure, Rod coater

Suggested drying condition Hot Air Dryer

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Coatings for PE replacement in paper cups

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Recommended application conditions

Paper Board Cup stock 140 – 300 gsm

Cup sealing condition 2 bar pressure / 140 ~ 180°C

Ultrasonic Sealing Same as existing extruded PE Cup forming settings

Cup sealing speed 40 – 150 cups/min

30 minutes cobb value 2 g/m2

3M Kit Value 10

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Coatings for Staple-free Tea bags

Why switch to staple free Tea bags?

• Staples in Tea bags can be hazardous

• FSSAI ban of staple pins

How coatings can help?

• Water based coatings can be used as a replacement to staple

pins

• Heat Sealable

• FDA approved for Direct food contact.

• Recyclable & Repulpable

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Tea bag with staples Staple Free teabags

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Future trends in Paper packaging

High/Ultra High barrier

• Paper based packaging for demanding applications

• Applications Detergent, Coffee, Dry foods, Dehydrated foods

• Challenges – Inherent poor barrier of paper, viability due to high coat weights

Strength – Large pack sizes, transit performance

• Paper with high burst strength, resistance to drops, cracking & puncture

• Applications – Detergent, Coffee, Dry foods, Dehydrated foods

• Challenges – Sealing, fibre tear at low 0.9 – 1.3 kgs

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Collaboration Opportunity

• Open to Paper Mills, brand owners, print converters & film manufacturers.

• Sustainable water-based chemistry, greener solutions

• World-class talent & global expertise

• Rapid prototyping for reduced concept-to-commercialization time

State of the art packaging incubator

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• Infrastructure for training on coatings

• Application lab

• Formulation lab

• Kroenert dual-station pilot coating line

• Finishing capability

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Michelman Innovation Centre for Coatings

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• Cold-blending capabilities

• Ultrasonic stirrer

• Block tester

• Drying ovens

• Extraction fume hood

• Rod coaters

• Viscosity meters

Formulation Lab

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Equipped for comprehensive testing of packaging structures

• Hot tack testing

• Mocon® OTR/MVTR testing

• Sealing machine

• Corona treatment

• Gelbo tester

Application Lab

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• Gravure, Flexo & Mayer rod technology

• Water-based, solvent-based & UV Technology

• Chambered doctor blade

• 6 micron to 400 gsm

• 510 mm width

• Hot nip laminator

Kroenert Dual Station Pilot coating line

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Michelman Innovation Centre For Coatings

VIDEO

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Michelman Innovation Centre For Coatings

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THANK YOU !!

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