From plastic to paper: how barrier coatings are reducing environmental footprints

As environmental concerns continue to rise, the demand for sustainable packaging solutions is growing—driven not only by industry efforts but also by increasing consumer preference for paper-based and recyclable alternatives.

Plastic waste, particularly single-use plastic, is a significant contributor to pollution and this growing problem has spurred a shift towards more eco-conscious solutions like paper and board. In particular, barrier coatings have emerged as a game-changing innovation for printers and converters in this sector that enable significant reductions in packaging’s environmental impact.

The environmental challenges of traditional packaging

Plastic packaging ‘s environmental impact needs no introduction. The longevity of non-recyclable materials in landfills makes it a contributor to global pollution, and its creation and disposal can result in the release of pollutants and greenhouse gases. Although its versatility is undeniable, plastic’s environmental drawbacks underscore the need for alternatives that balance performance with a lower carbon footprint.

Finding sustainable alternatives to plastic in packaging presents unique challenges. Many eco-conscious materials struggle to provide the necessary durability or barrier properties for effective packaging, especially for food packaging applications. This is where Flint Group’s barrier coatings come in – offering an innovative solution, enhancing the performance of paper packaging with reliable barrier properties while supporting sustainability goals.

The role of barrier coatings

Barrier coatings are thin layers of specialised consumables applied to substrates to enhance their resistance to external factors such as moisture, grease, oxygen, and vapours. These coatings help to improve the durability and functionality of packaging materials, and can enable paper-based substrates to reduce plastic use in various applications. Barrier coatings can be made via water-based solutions or natural compounds, ensuring that paper-based packaging remains recyclable, compostable, or biodegradable while enhancing its protective qualities.

Types of eco-conscious barrier coatings

One key requirement for many packaging materials is their ability to resist oils, greases, and fats. Water-based barrier coatings provide a more sustainable alternative to commonly used PE coated paper solutions. These coatings deliver superior oil and grease resistance than paper alone, and are ideal for a wide range of packaging applications.

Water resistance and moisture vapour resistance play distinct but complementary roles in sustainable packaging. Water-resistant coatings are designed to shield fibre-based materials from external moisture, such as rain or condensation, preserving the integrity and appearance of the outer packaging. On the other hand, coatings with low Moisture Vapour Transmission Rates (MVTR) serve to protect the internal contents by preventing moisture ingress that could compromise sensitive products. Together, these barrier properties help maintain both the durability of the packaging and the quality of the goods inside—crucial in humid environments or during extended storage and transport.

Environmental benefits

To meet barrier requirements, paper-based packaging often incorporates multi-material structures such as a combination of paper and polyethylene (PE). However, these mixed materials can be challenging to recycle because the layers cannot be recycled together in a single stream.

Unlike traditional plastic laminates that complicate waste management, paper products coated with a water-based barrier coating remain easy to repulp and reuse. This innovation both helps to reduce plastic waste and also minimises packaging’s carbon footprint by reducing reliance on components derived from fossil fuels.

What’s more, barrier coatings applied to paper-based substrates can significantly enhance packaging’s compostability. For example, water-based coatings applied to paper and board packaging can decompose more readily than their plastic counterparts while maintaining safety for food contact applications.

Industries leading the charge

Barrier coatings are already being widely used across a range of sectors:

• Food and beverage packaging: From takeaway containers to coffee cups, barrier coated paper products offer high grease and moisture resistance while being better for the environment.
• Retail and e-commerce: Protective coatings on paper mailers improve durability without requiring plastic.
• Industrial applications: Bulk goods can now benefit from paper-based barrier solutions that reduce the need for traditional plastic wraps.

Challenges and future outlook

Functionality and performance present common limitations compared to the current film structures, and research to overcome these is ongoing. However, the advancements being made by companies like Flint Group are expanding the capabilities of these products, and with increased regulatory support for more sustainable packaging solutions, the adoption of barrier coatings is expected to grow significantly in the years to come.

Conclusion

Flint Group’s barrier coating solutions from the DecaCode range, demonstrate the value of these products to today’s Paper & Board industry.  These coatings enhance the performance and recyclability of paper-based substrates, offering printers and converters a sustainable solution to meet evolving packaging demands while reducing reliance on plastic. As businesses and consumers alike increasingly demand more eco-conscious choices from their packaging, barrier coatings represent an important step towards a more responsible future.

To find out more about how Flint Group’s barrier coating technologies can transform your packaging operations, contact your local Paper & Board sales representative.