Sustainable coating solutions for

Paper & Paper board

Shailesh Nema – Vice President & Managing Director

IIPTA 55th Annual General Meeting & Seminar– Ahmedabad, 8th & 9th March 19

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 What is Sustainable Packaging?

• Beneficial, safe & healthy for individuals and communities throughout its life cycle

• Sourced, manufactured, transported, and recycled using renewable energy

• Optimizes the use of renewable or recycled source materials

• Manufactured using clean production technologies and best practices

• Physically designed to optimize materials and energy

• Meets market criteria for performance and cost

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Growing demand for Sustainability

• Legislation & regulations

Pushing for innovative eco-friendly & Sustainable packaging

• Consumer awareness
Millennials, purchasing power is rapidly on the rise and are
especially interested in choosing socially and
environmentally responsible brands

• Conscious capitalism
Businesses committing to be environmentally conscious

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Paper in packaging – Benefits & Limitations

Benefits

• Recyclable
• Biodegradable
• Shelf appeal

Limitations

• Natural source
• Strength & Non Flexible
• Poor- Barrier properties
• Once barrier properties are improved, Paper can be a good alternative to plastic.

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Recyclable solutions for Paper & Paperboard

• Water Based coatings

• Green solutions, Eco- Friendly

• Improves and enhances barrier properties

• FDA approved

• APEO free

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Benefits of water based coatings

Barrier properties

• Coatings can improve paper's barrier properties which is a crucial step in increasing its
viability as a packaging material

• Barrier coatings can help in achieving the OTR & MVTR values required for dry food products

• MVTR – 10 gms/m2/24 hr

• OTR – 70 cc/m2/24 hr

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Applications - Barrier properties

MVTR < 10

OTR < 80
MVTR < 10

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Benefits of water based coatings

Oil & Grease Resistance

• Coatings enhance oil & grease resistance in Paper

• Acts as freshness barriers

• Keeps perishables safer over a longer period of time

• Recyclable & Repulpable

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Application- Oil & Grease Resistance

3M KIT >10 3M KIT >9 3M KIT >10

3M KIT > 8 3M KIT > 8

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Benefits of water based coatings

Water Repellent
• Environmentally friendly

• Imparts water repellant property to paper

• Heat Sealable

• Recyclable & Repulpable

• FDA complaint

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Application - Water repellent

COBB < 10

COBB < 10

COBB < 10 COBB < 10

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Water based coatings for Aesthetics

• Coatings can improve the Aesthetics of the

paper/final product

• Haptic coatings can enhance the look and feel of

the product

• Shelf appeal

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 Brand Backlash

March 22, 2017 March 20, 2018

• Starbucks is teaming up with Closed Loop

Partners‘ Center for the Circular Economy to
create the NextGen Cup Challenge.

• The challenge will award grants to

entrepreneurs working on ideas that could lead
to the development of more sustainable cups.

• The challenge represents a the first step toward

keeping cups out of landfills and making them
recyclable or compostable. Whatever solutions
come out of the challenge will be open source,
to encourage other coffee companies to join in.

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Coatings for PE replacement in paper cups

• Eco-friendly alternative to plastic cups

• Recyclable, Re-pulpable

• Food Grade, FDA Certified for direct food contact

• 2 stage coating process, with coat weight as low as 4gsm

• Energy efficient, seals at lower temperatures than PE

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Biodegradable solution
Weight Loss (Soil Burial) Test Results

Date of Start: 15-Nov-2018 No. of Days: 105

Date of Report: 28-Feb-2019 Test Standard Followed: Party’s Request

Material Initial Wt., gm Final Wt., gm Weight Loss (%)

Coated Paper 13.88 1.85 86.67

Biodegradability Test Results

Date of Start: 13-Feb-2019 No. of Days: 15

Date of Report: 28-Feb-2019 Test Method Followed: IS/ISO 14855-1

Material Biodegradation (%)

Coated Paper 29.88

Source: Indian Institute of Packaging

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Coatings for PE replacement in paper cups

Coating details
Base coat
Base coat weight 2 gsm / dry
Solid Content 53%
Recommended coating method Gravure, Rod coater
Recommended drying condition Hot Air Dryer
Top coat
Top coat coating weight 2 gsm / dry
Solid Content 53%
Suggested coating method Gravure, Rod coater
Suggested drying condition Hot Air Dryer

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Coatings for PE replacement in paper cups

Recommended application conditions

Paper Board Cup stock 140 – 300 gsm
Cup sealing condition 2 bar pressure / 140 ~ 180°C
Ultrasonic Sealing Same as existing extruded PE Cup forming settings
Cup sealing speed 40 – 150 cups/min
30 minutes cobb value 2 g/m2
3M Kit Value 10

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Coatings for Staple-free Tea bags

Why switch to staple free Tea bags?

• Staples in Tea bags can be hazardous

• FSSAI ban of staple pins

How coatings can help?

• Water based coatings can be used as a replacement to staple

Tea bag with staples Staple Free teabags
pins

• Heat Sealable

• FDA approved for Direct food contact.

• Recyclable & Repulpable

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Future trends in Paper packaging

High/Ultra High barrier

• Paper based packaging for demanding applications

• Applications Detergent, Coffee, Dry foods, Dehydrated foods

• Challenges – Inherent poor barrier of paper, viability due to high coat weights

Strength – Large pack sizes, transit performance

• Paper with high burst strength, resistance to drops, cracking & puncture

• Applications – Detergent, Coffee, Dry foods, Dehydrated foods

• Challenges – Sealing, fibre tear at low 0.9 – 1.3 kgs

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Collaboration Opportunity

State of the art packaging incubator

• Open to Paper Mills, brand owners, print converters &

film manufacturers.

• Sustainable water-based chemistry, greener solutions

• World-class talent & global expertise

• Rapid prototyping for reduced concept-to-

commercialization time

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Michelman Innovation Centre for Coatings
• Infrastructure for training on coatings
• Application lab
• Formulation lab
• Kroenert dual-station pilot coating line
• Finishing capability

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Formulation Lab

• Cold-blending capabilities
• Ultrasonic stirrer
• Block tester
• Drying ovens
• Extraction fume hood
• Rod coaters
• Viscosity meters

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Application Lab

Equipped for comprehensive testing of packaging structures

• Hot tack testing

• Mocon® OTR/MVTR testing
• Sealing machine
• Corona treatment
• Gelbo tester

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Kroenert Dual Station Pilot coating line

• Gravure, Flexo & Mayer rod technology

• Water-based, solvent-based & UV Technology
• Chambered doctor blade
• 6 micron to 400 gsm
• 510 mm width
• Hot nip laminator

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Michelman Innovation Centre For Coatings

VIDEO

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Michelman Innovation Centre For Coatings

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THANK YOU !!

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