Barrier Coatings for Paper using CelluBlend Technology

Overview

ZeroPlast Labs' CelluBlend technology offers a sustainable alternative to conventional plastic coatings for paper packaging. By modifying cellulose and nanocellulose into ethers, esters, and tailored emulsions, the technology delivers water vapor and oxygen barrier properties suitable for long-term packaging applications. A 20 GSM coating of the CelluBlend material has demonstrated performance equivalent to LDPE-coated paper across water resistance, grease resistance, thermal stability, heat-sealability, and food-safety, validated by certified laboratories.

This solution addresses growing demand from packaging converters and brand owners for recyclable, compostable, and repulpable barrier coatings that can replace single-use plastics without sacrificing performance.

Technical specifications

• Material platform: Modified cellulose and nanocellulose derivatives (ethers, esters) produced through crosslinking and blending to form stable coating emulsions.
• Barrier performance: At 20 GSM coating weight, delivers water resistance, grease resistance, thermal stability, heat-sealability, and food-safety comparable to LDPE-coated paper.
• Sustainability profile: Repulpable, compostable, and designed to support circular paper recycling streams.
• Application method: Emulsion-based coatings compatible with existing paper coating infrastructure.
• Planned enhancements: Further modification with crosslinkers targeting remaining cellulose hydroxyl groups, and development of polymeric blend emulsions for broader coating versatility across paper grades.

Technology readiness level

The technology has reached an advanced validation stage. Independent certified lab testing has confirmed key barrier and safety properties, and side-by-side comparisons with LDPE-coated paper have validated competitive performance. Current development is focused on optimizing water vapor transmission rate (WVTR) and oxygen transmission rate (OTR) through additional crosslinking and blend formulation work, along with further validation of repulpability across paper recycling processes.