Low-permeability nanocellulose-graphene film laminates with flexographic top coating
Bio-based barrier film technology combining nanocellulose with graphene to achieve low water vapor and oxygen transmission rates. Designed for paper lamination and packaging applications, with optional flexographic top coatings for enhanced moisture resistance.
Overview
This solution addresses the need for high-performance, bio-based barrier films suitable for sustainable packaging and paper-based product protection. By combining nanocellulose (NC) with graphene (G), the technology produces thin films with significantly reduced water vapor transmission rate (WVTR) and oxygen transmission rate (OTR). The films are laminated onto paper substrates, and additional water resistance can be achieved through thin flexographic top coatings. This approach offers a renewable alternative to conventional fossil-based barrier materials.
Technical specifications
- Nanocellulose-graphene composite films: Nanocellulose acts as a film former with strong adhesion to paper, while graphene—impermeable to most gases—dramatically improves water vapor barrier performance even at low loading levels.
- Barrier performance achieved: WVTR below 5 g/(m²·day) at 50% RH and 23°C for 20 µm thin films, representing a reduction of two orders of magnitude compared to plain nanocellulose films.
- Lamination capability: Films can be laminated onto paper substrates for use in packaging and other paper-based barrier applications.
- Flexographic top coating: Very thin flexo-printed layers can further reduce WVTR, leveraging the already low permeability of the base NC-G film.
- Scalable production processes: RISE has developed energy- and cost-effective manufacturing processes for these films at larger scale, along with expertise in multi-layer barrier concepts.
Technology readiness level
The technology has been validated at lab scale with demonstrated WVTR performance below 5 g/(m²·day) for 20 µm films laminated to paper. Current work focuses on three work packages: further optimization of graphene-nanocellulose films (including cost effectiveness and migration evaluation), evaluation of flexographic top coatings for improved water resistance, and comprehensive characterization including OTR/WVTR, grease barrier, folding robustness, and food simulant migration testing. The institute has experience in both lab-scale and full-scale flexographic printing applications. Further development is needed to reach the targeted WVTR and validate the technology for industrial deployment.
About Forestry Research Institute of Sweden
Skogforsk is Sweden’s national applied institute for forestry, headquartered in Uppsala Science Park with additional locations in Sävar and Ekebo. Industry integration is built in: core programs are co‑financed under a long‑term framework where the forestry sector and the state each fund half, enabling rapid, deployment‑oriented pilots. The institute convenes companies and equipment makers around interoperable data and machine standards, coordinating the StanForD harvester data standard, and provides contract research, field trials, and training. Funding combines the government–industry framework with additional grants and fee‑for‑service work. A structured partner program and knowledge‑transfer services support implementation at scale.
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