Graphene-enhanced bio-based compostable barrier films for paper substrates
Versarien offers graphene nanoplatelet (GNP) enhanced bio-based coatings for paper substrates that deliver up to 90% reduction in water vapor transmission rates while maintaining EN13432 compostability. The technology combines graphene with PVOH and cellulosic binders to create tortuous-path barriers against water and oxygen migration, suitable for sustainable packaging and barrier paper applications.
Overview
Versarien has developed graphene nanoplatelet (GNP) enhanced bio-based coatings designed to significantly improve the barrier properties of compostable paper substrates. The technology leverages the atomic structure of graphene to create a tortuous path that impedes the migration of water vapor and oxygen molecules through coated paper. When dispersed within bio-based polymer matrices such as polyvinyl alcohol (PVOH) and cellulose, the graphene nanoplatelets deliver barrier performance improvements of up to 90% in water vapor transmission rate (WVTR) compared to uncoated controls.
The solution addresses a critical market need for sustainable packaging materials that provide effective barrier protection without compromising compostability. Versarien's graphene has already passed EN13432 composting certification, tested by OWS Belgium, confirming that the material can be incorporated into fully compostable packaging systems. This makes the technology particularly relevant for brands and packaging converters seeking to replace conventional plastic barriers with environmentally responsible alternatives.
Technical specifications
Core technology:
- Graphene nanoplatelets (GNPs) with large lateral flake size dispersed in bio-based polymer matrices
- Tortuous path barrier mechanism that physically impedes water vapor and oxygen molecule migration
- Compatible binder systems including PVOH and cellulosic (cellulose/starch) coatings
Application methods:
- Wire-wound bar coating technique for controlled film deposition
- Variable coat weight application (various gsm levels tested)
- Multi-layer coating approaches for enhanced barrier performance
- Optional mild calendering post-application to improve surface consolidation
Performance results:
- 90% reduction in WVTR versus control samples
- OTR testing conducted alongside WVTR evaluation
- SEM examination used to identify and minimize coating defects and pinholes
- Graphene loading levels up to 5% validated for compostability compliance
Sustainability credentials:
- EN13432 composting certification achieved (tested by OWS, Belgium)
- Fully recyclable and compostable paper substrate compatibility
- Bio-based binder systems supporting renewable material targets
Technology readiness level
The technology is currently at an advanced proof-of-concept stage with promising validated results. Three different graphene types have been blended into PVOH and cellulosic matrices and successfully applied to paper substrates. Testing has demonstrated consistent 90% WVTR reductions compared to controls, with SEM analysis confirming coating integrity.
Future development is structured around five planned work packages covering baseline substrate characterization, coating process trials, binder optimization with cellulose/starch and PVOH systems, and multi-layer film development. Versarien is seeking partners for collaborative R&D with engagement options including a 3-month proof-of-concept (£25,910), 6-month (£48,021), or 12-month (£92,241) project structure. The technology is ready for pilot trials with end-customer paper substrates and offers a pathway to commercial-scale compostable barrier paper products.
About Versarien
Versarien plc is an intellectual property-led advanced engineering materials group that develops and manufactures innovative solutions based on proprietary technology. The group operates through multiple subsidiaries that specialize in the production and application of advanced materials, including graphene and tungsten carbide. By leveraging scientific research and its internal manufacturing capabilities, Versarien aims to transform intellectual property into commercially viable engineering products. The company focuses on expanding its material portfolio, establishing licensing arrangements, and acquiring companies that align with its goal of commercializing advanced materials technology across diverse industrial sectors.
These material solutions are designed to address specific technological and engineering challenges faced by modern manufacturers, offering potential improvements in areas such as energy storage and industrial application performance. Through its subsidiaries, Versarien provides industry sectors with graphene-enhanced products and other engineered nanomaterials. The group maintains a focus on verification and quality standards, having been the first company to achieve the Verified Graphene Producer certification. By providing working capital, plant, and operational expertise, the company works to integrate these advanced materials into existing industrial supply chains, solving material-related problems for its customers and partners.
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