Shellac-coated cellulose barrier materials via papermaking, electrospray, and laser processing

Overview

This research proposes a novel approach to creating high-performance, sustainable vapor barrier materials using cellulose-based substrates combined with shellac coatings. The technology addresses the growing need for recyclable and bio-based barrier materials in packaging applications. By integrating three key processing techniques—papermaking with multi-scale cellulose fibers, self-limiting electrospray deposition (SLED) of shellac, and laser-based surface processing—the team aims to produce barrier materials with tunable permeability, hydrophobicity, and recyclability. The approach offers a potential pathway to replace petroleum-based barrier coatings with renewable alternatives while maintaining or improving performance characteristics.

Technical specifications

Key technology components:

• Multi-scale cellulose substrates: Micro-fibrillated cellulose (MFC) and nano-fibrillated cellulose (NFC) combined with cellulose acetate in layered constructs to control tortuosity, porosity, and surface smoothness
• Self-limiting electrospray deposition (SLED): A novel technique that deposits shellac coatings with controlled thickness, enabling pore plugging and hydrophobic surface formation
• Laser-based processing: Femtosecond lasers for gentle surface smoothing and nanosecond lasers for roughening or ablating shellac coatings to enable recycling
• Barrier property characterization: Coordinated measurement of vapor permeability across different coating thicknesses, roughness levels, and pore structures

The team comprises four Rutgers faculty members with complementary expertise: handsheet formation and cellulose nanocomposite tuning, electrospray coating development, laser surface processing, and polymer nanocomposite barrier characterization. The Rutgers Packaging Engineering Program provides additional support.

Technology readiness level

This is an early-stage research project at Technology Readiness Level (TRL) 2-3, focused on hypothesis validation and proof-of-concept development. The proposed one-year project will systematically evaluate whether the synergistic combination of these three processing techniques can achieve tunable vapor barrier properties. Validation will proceed through coordinated fabrication and characterization: cellulose-based sheets will be formed, coated with shellac via electrospray, processed with laser energy, and characterized for barrier performance. The research builds on validated expertise from each team member but represents an untested combination of techniques. Success would establish the foundation for subsequent scale-up and commercialization efforts in sustainable packaging applications.