Sustainable clay nanoplatelet barrier technology for recyclable paper-based packaging
A nano-barrier coating technology combining clay nanoplatelets and binder systems applied to paper, board, or moulded fibre substrates. Designed as a drop-in replacement for single-use plastics, delivering water vapour barrier performance with recyclable, home-compostable, and biodegradable end-of-life characteristics for food and non-food packaging.
Overview
This technology offers a sustainable barrier coating for paper-based packaging, combining precisely arranged clay nanoplatelets with a functional binder to create a highly effective water vapour barrier. The nanoplatelets form a tortuous path that slows moisture transmission, while the binder delivers the flexibility needed for converting and end-use performance. Applied to the external surface of substrates, the barrier provides continuous protection during use and supports optimised end-of-life behaviour once the pack is opened.
The solution is designed to replace single-use plastics across both food and non-food applications, working with flexible paper, semi-rigid board, and rigid moulded fibre substrates. It supports recyclable, naturally compostable, and cost-effective packaging formats, offering brands a commercially viable alternative to conventional plastic barriers without requiring specialised waste streams.
Technical specifications
- Tortuous path barrier mechanism: Clay nanoplatelets arranged within the coating create a physical maze that significantly slows the passage of water vapour through the substrate.
- Binder flexibility: A binder component delivers functional flexibility to the barrier layer, enabling converting, forming, and sealing on standard packaging lines.
- Substrate compatibility: Successfully applied to base paper (flexible), board (semi-rigid), and moulded fibre (rigid) materials.
- Current barrier performance: Water vapour transmission rate at 25°C/75%RH meets medium-tier packaging targets, with ongoing development targeting high-tier specifications.
- Testing conditions in development: Transitioning from 25°C/75%RH to more demanding 38°C/90%RH conditions, with combined WVTR and oxygen transmission rate (OTR) capabilities in development.
- End-of-life performance: Preliminary recyclability testing has returned A to A+ grades for flexible formats, and soil degradation/compostability testing has shown 100% degradation within eight weeks.
- Material transparency: The formulation currently includes a latex binder component that is not in direct contact with packaged product.
Technology readiness level
Proof of concept, process prototyping, and equipment prototyping have been completed. Lab-scale process development, sampling, and preliminary short-run production trials have been successfully undertaken, with the barrier technology applied and tested across flexible, semi-rigid, and rigid substrate formats. Development is now transitioning to pilot-scale equipment, including standard and proprietary modular systems, with continuous improvement initiatives underway to expand barrier performance and broaden substrate and binder options.
About Envirobalance Technologies Ltd
Envirobalance Technologies Ltd develops sustainable, paper-based packaging designed to replace single-use plastics. The company utilizes a patented nano-barrier technology that is integrated directly into the paper during manufacturing, providing protection against water vapor, gases, aromas, and UV light while maintaining high performance. This material is designed to be 100% biodegradable, home compostable, and recyclable, offering a functional, natural alternative that degrades harmlessly in land or ocean environments. The company's technology is engineered to match or exceed the barrier properties of existing plastics, enabling shelf lives of up to 20 weeks for various food and non-food applications.
The solution is intended to address the global environmental impact of plastic pollution by providing a commercially viable, drop-in replacement compatible with existing manufacturing and packaging methods. By focusing on sustainable materials that do not require specialized waste streams, Envirobalance aims to support a zero-impact packaging future for industries such as food processing, beverages, and retail. The technology is applicable to both flexible and rigid packaging formats, utilizing either virgin or post-consumer materials to ensure cost-effectiveness for partners and customers. Founded in 2018, the company leverages extensive expertise in mechanical engineering, intellectual property, and industrial packaging systems to drive the adoption of its plastic-free alternatives.
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