Recyclable and compostable high barrier paper for flexible packaging

Overview

Sustainable Packaging Products Ltd (SPP Ltd) has developed high barrier papers and boards as sustainable replacements for plastics in food flexible packaging applications. The technology targets brand owners and converters seeking to meet sustainability commitments without sacrificing the functional performance demanded by modern food packaging, including shelf life protection and machinability on form, fill, and seal equipment.

Technical specifications

Core technology: A multi-layer coating process combined with advanced drying techniques that enables the application of novel coatings onto paper substrates.

Functional properties delivered:

• Heat sealability for form, fill, and seal converting
• High grease resistance (Kit 12 plus)
• Water resistance (Cobb1800 below 2 gsm)
• Moisture vapour barrier (MVTR below 1.0 gsm/day at 23°C, 85% RH)
• Oxygen barrier (below 1.0 cc/m²/day at 23°C, 0% RH)
• Excellent print surface for high quality graphics
• Conventionally repulpable in standard paper recycling streams
• Compostable options available

Process maturity: Over 400 laboratory samples have been produced and validated, and five production machine trials have been completed, each generating approximately 2,000 square metres of material. Independent third party laboratories have confirmed repulpability and barrier performance, and converter partners have successfully printed and formed the material into pre-formed pouches.

Technology readiness level

The technology has progressed beyond laboratory validation through multiple production scale trials on commercial converting equipment. Next stage development will focus on scaling two specific product variants: one optimised for high moisture barrier (MVTR below 1.0 gsm/day at 38°C, 90% RH) and one for high oxygen barrier (below 1.0 cc/m²/day at 23°C, 0% RH). Both variants will be produced on a production machine to supply material for full conversion trials and shelf life assessment testing, positioning the solutions for early commercial qualification.