Food-grade wax impregnation for hydrophobic paper-based packaging materials

Overview

This technology impregnates paper and board substrates with food-grade waxes and sizing agents to create hydrophobic, mechanically robust materials suitable for food packaging and disposable goods. The approach uses significantly less chemical than traditional paper-coating processes because the entire substrate is treated with functional chemical rather than only the surface, reducing waste and improving efficiency. By partially filling the pores between cellulose fibers, the treatment preserves breathability while delivering strong water resistance, making it attractive for sustainable packaging applications.

Technical specifications

• Hydrophobicity: Impregnation with alkyl ketene dimers (AKD) and other food-grade waxes achieves a uniform contact angle of approximately 140 degrees, placing the material in the sticky hydrophobic region.
• Mechanical strength: FTIR studies indicate enhanced hydrogen bonding within the cellulose network, contributing to improved storage moduli and overall material strength.
• Breathability: SEM imaging shows partial filling of the pores between cellulose fibers, allowing the paper to retain breathability while gaining hydrophobicity.
• Chemical efficiency: Uses less chemical input than conventional coating methods and generates less waste by treating the full substrate rather than only the surface.
• Validation approach: Impregnation studies monitored for up to six months confirm durable hydrophobic performance over extended storage.

Technology readiness level

The technology has been validated at the laboratory scale using filter paper substrates, demonstrating consistent hydrophobicity, improved mechanical properties, and preserved breathability over six-month monitoring periods. The next stage of development will extend these studies into commercial paper-based substrates suitable for packaging and disposable cups, with additional assessment of oleophobicity and mechanical strength. Potential partnerships include access to commercial raw material substrates, funding for testing personnel, and joint development of pilot-scale impregnation equipment for online or offline processing.