Clear fda-approved nanoclay barrier coatings for recyclable mono-pe flexible film laminates

Overview

NOVA Chemicals has developed a clear barrier coating solution for flexible film laminates that enables fully recyclable mono-polyethylene structures without the need for non-PE coextrusion layers, metallization, or compatibilizing additives. The technology targets food-contact packaging applications such as premade pouches, form-fill-seal bags, and lidding films, where it delivers both oxygen and moisture barrier performance while maintaining excellent optics and abuse resistance. The laminate has received Association of Plastic Recyclers (APR) Critical Guidance approval, meaning it is admissible into PE flexible recycling streams through both municipal and store drop-off collection systems.

Technical specifications

Core technology:

• Water-based nanoclay coatings applied via gravure coating onto biaxially oriented PE carrier films
• The biaxially oriented PE film surface provides the smoothness required for proper platelet orientation in the barrier layer, which conventional PE films cannot achieve
• A two-film laminate design pairs an oxygen-barrier PE print web with a moisture-vapor-barrier PE sealant film

Performance characteristics:

• Oxygen transmission rate (OTR) as low as 0.06 cc/100 in²
• Moisture vapor transmission rate (MVTR) below 0.1 g/100 in²
• FDA-approved for food contact
• Excellent resistance to gas and flavor ingress and egress at elevated temperature and humidity
• Recycled PE content can be incorporated into the laminate structure

Processing benefits:

• Compatible with standard printing and lamination converting processes
• Suitable for premade pouch, form-fill-seal, and lidding film applications
• Maintains package optics and abuse resistance comparable to or better than metallized or EVOH-based alternatives

Technology readiness level

This technology has been commercialized through the coating supplier and existing customers, with multiple large integrated packaging suppliers in North America already adopting it. The solution is ready for broader market rollout. Ongoing development efforts focus on new film substrates with higher surface gloss to further improve barrier performance or reduce coating weight, along with continued formulation updates from the coatings partner.