Heat-Tolerant Water Barriers Based on Wax-Polysaccharide Composites

We developed aqueous wax emulsions and investigate their use in liquid barrier treatments for various substrates including paper and pulp molding. Our work combined formulation screening, emulsion characterization, and application testing with an industrial partner. This experience provides a solid research foundation for developing wax/polysaccharide systems for heat-tolerant, plastic-free liquid water barriers. Our previous project screened various biowax and microcrystalline wax emulsions, varied emulsifier blends and processing conditions, and evaluated combinations with starch derivatives, chitosan, and sodium alginate. We examined both surface coating and internal sizing approaches. Formulation variables included wax grade, emulsifier balance, solids content, pH, and addition sequence, with attention to dispersion, flow behavior, and phase separation. We're past pilot scale within 12 months. Our characterization work included FTIR and SEM comparisons, particle-size & distribution and Zeta-potential measurements of reference emulsions. Laboratory coating trials and repeated sample submissions to an industrial partner provided feedback on water and oil penetration, including hot-liquid exposure. Some application trials reported no visible penetration with boiling water, while other formulations leaked or showed inadequate emulsion stability. These results identified useful formulation variables and failure modes. For this opportunity, we propose to focus on natural waxes combined with polysaccharide components, selecting every ingredient against a strict plastic-free definition. Earlier experimental formulations containing synthetic polymer components would not be carried forward without reformulation and review. The development aim is to combine wax-mediated water repellency with a coherent polysaccharide-containing barrier while maintaining workable emulsion stability and processing behavior. Next steps would be to agree on the target substrate, liquid-contact duration, application method, and acceptance criteria, then screen candidate formulations and evaluate liquid water resistance at approximately 88°C. Testing would assess leakage or water uptake, coating integrity after heating and folding, and emulsion storage stability. My research team includes 7 professors/associate professors, as well as 50+ graduate students and postdoctoral fellows. We have been engaged in this research field for over 15 years. Our team has a very strong foundation in preliminary research and looking forward to our collaboration.