Polypop: sustainable polyester barrier coatings from waste polyethylene

Overview

Polypop is an innovative solution designed to convert waste polyethylene into long-chain dicarboxylic acids (C12–C22) through selective oxidative depolymerisation. These acids serve as precursors for aliphatic polyester coatings that are PFAS-free, hydrophobic, and potentially repulpable. The coatings are targeted for use on paper substrates, providing moisture and grease resistance without the need for fluorination, and are formulated for compatibility with high-speed converting lines. This technology leverages waste flexible film as a feedstock, aligning with sustainability goals and offering a strong life cycle assessment (LCA) position.

Technical specifications

• Core Technology: Conversion of waste polyethylene into long-chain dicarboxylic acids for polyester coating production.
• Key Features:
  • PFAS-free and inherently hydrophobic
  • Grease resistance provided by long alkyl chains
  • Potentially repulpable at low coating weights (less than 5% non-fibre content)
  • Targeted for aqueous or dispersible coatings on paper substrates
  • Compatible with high-speed converting lines
• Applications: Suitable for paper packaging that requires moisture and grease barriers, particularly in high-frequency sealing (HFFS) and single-use packaging (SUP) applications.

Technology readiness level

Currently at Technology Readiness Level 3, Polypop is in the early stages of development, with polymer formulation yet to be completed. The technology has a clear roadmap for advancement and is seeking co-development partnerships to validate coating performance and generate essential barrier and mechanical data.