Recyclable high-barrier paper packaging for dry food products

Overview

This solution offers a recyclable, high-barrier paper-based sachet designed for dry food packaging. The packaging combines 80% paper with fully biobased and/or biodegradable barrier coating layers, achieving high moisture resistance, oxygen barrier, and grease resistance. It functions as a drop-in replacement for conventional multilayer packaging, designed for easy recycling within existing paper waste streams and compatible with current form-fill-seal (FFS) packaging lines. The technology addresses the consumer packaged goods industry's growing demand for circular and cleaner packaging without sacrificing barrier performance.

Technical specifications

Material composition:

• Minimum 80% paper content from commercially available grades (45–90 gsm)
• Aqueous dispersion primers for enhanced adhesion
• Ultra-thin inorganic barrier layer deposited via physical vapor deposition (PVD)
• Heat seal and moisture barrier layer using aqueous dispersion and/or extrusion coating

Performance metrics:

• Oxygen transmission rate (OTR): less than 0.05 ml/(m²·day) at 23°C and 50% relative humidity
• Water vapor transmission rate (WVTR): less than 1.5 g/(m²·day) at 38°C and 90% relative humidity
• Sealing strength: up to 7.5 N/15mm
• Up to 80% repulpability verified through PTS recyclability testing

Key advantages:

• Drop-in compatibility with existing FFS packaging lines
• Food compliance of all materials
• Cost-effective sourcing with guaranteed material availability

Technology readiness level

The technology is currently at TRL 6, validated through pilot-scale reel-to-reel production of several hundred meters. Pilot-scale coating trials have been completed, and industrial-scale production is underway, with industrial-size reels being produced in an industrial environment targeted for readiness by the end of 2024. Validation for dry food applications is complete, with wet food validation ongoing. Future development activities include optimizing layer interactions and synergistic barrier effects, refining coating formulations, down-gauging layer thicknesses to increase paper ratio, conducting additional shelf-life tests, and finalizing recyclability and life cycle assessment (LCA) evaluations.