Biobased barrier coating eliminates PFAS, achieving Kit 12 TAPPI grease resistance.

Background

The packaging industry heavily relies on barrier films and surface coatings to protect goods from moisture, oil, and grease. These barriers are essential for maintaining product integrity, extending shelf life, and preventing contamination in food service and consumer goods. As global awareness of environmental sustainability grows, there is an urgent need for eco-friendly packaging solutions. Consumers and regulatory bodies are demanding materials that are biodegradable, derived from renewable resources, and capable of matching the performance of traditional materials without leaving a lasting ecological footprint.

Despite this clear need, current approaches to manufacturing barrier coatings predominantly rely on synthetic, fossil-fuel-derived polymers and hazardous chemicals. The most common solutions utilize polyethylene films or per- and poly-fluoroalkyl substances (PFAS) to achieve the necessary oil and water repellency. However, these conventional materials present severe environmental and health challenges. Polyethylene is non-biodegradable, contributing significantly to long-term plastic pollution in landfills and oceans. Furthermore, PFAS are highly toxic, persist indefinitely in the environment, and bioaccumulate in the food chain. The continued use of these synthetic coatings exacerbates global waste crises and poses significant toxicity risks.

Technology

This technology provides biobased, biodegradable barrier films and coatings derived from agricultural by-products like spent distillers grain and oil extraction pomaces. The manufacturing process treats these plant-based feedstocks with water or alkali at elevated temperatures, followed by homogenization or microfluidization to create a gel-like product or isolated protein fractions. To enhance mechanical and barrier properties, the formulation can be blended with waxes, metallic minerals, and crosslinkers like citric acid. The resulting materials are applied to paper substrates to provide robust oil, grease, and water resistance.

This solution is highly differentiated by its ability to replace hazardous, fossil-based synthetic coatings, such as PFAS and polyethylene, with a completely sustainable, plant-derived alternative. By upcycling agricultural waste, it leverages natural proteins and oils to achieve exceptional performance without compromising the environment. When applied as paper coatings, these materials demonstrate superior hydrophobicity, achieving water contact angles exceeding 90 degrees and reducing wettability by up to 90%. Furthermore, the coatings deliver maximum oil and grease resistance, scoring a perfect kit rating of 12 on standard industry tests.

Benefits

• Provides a sustainable, biodegradable, and non-hazardous alternative to harmful synthetic coatings like PFAS and fossil-based polyethylene films.
• Promotes a circular economy by upcycling protein- and oil-rich agricultural by-products, such as spent brewery and distillery grains, into high-value materials.
• Delivers exceptional oil and grease barrier performance, achieving maximum resistance ratings (TAPPI kit rating of 12) for packaging applications.
• Exhibits strong hydrophobic properties, demonstrating high water contact angles (over 90 degrees) and significantly reduced water wettability.
• Offers highly versatile and customizable formulations that can be tailored with natural waxes, minerals, or crosslinkers and processed into films, paper coatings, or fibers.

Applications

• Grease-resistant food packaging
• PFAS-free paper cups
• Biodegradable fast food wrappers
• Water-resistant paperboard shipping boxes
• Sustainable agricultural mulch films

Additional info

These biobased barrier films, coatings, and fibers are produced by treating protein- and oil-rich agricultural by-products with water or alkali at elevated temperatures. Processing involves homogenization or microfluidization, yielding gels at pH above 11.0 or precipitated proteins below pH 11.0. Formulated with 1% to 50% wax, metallic additives, and crosslinkers like citric acid, the resulting hydrophobic materials exhibit water contact angles exceeding 90 degrees and high grease resistance.