Next-gen bio-based barrier coating for fiber packaging

We are pleased to present this conceptual proposal for a 100% bio-based, marine/soil/home-compostable, and fully repulpable barrier coating engineered specifically for paperboard extrusion processes. By combining high-degree-of-substitution (DS) starch esters with upcycled cellulose nanocrystals (CNCs) from post-consumer paper streams, this solution replaces fossil-based polyolefins (PE/PP) while satisfying all project performance mandates. The proposed resin utilises a thermoplastic starch ester matrix (DS 1.8–2.5) plasticised with non-volatile bio-esters (Acetyl Tributyl Citrate - ATBC) and reinforced with 3–8 wt% upcycled Cellulose Nanocrystals (CNCs). This composite overcomes historical limitations of polysaccharides by conferring true melt-flow behaviour at 150–165°C without thermal degradation.