novel base coat for water-based barrier systemsbarrier systems · overview of novel base coat for...

Novel Base Coat for Water-BasedBarrier SystemsBarrier Systems

Tom HannigengGlobal Business Development ManagerAshland Hercules Water Technologies

PaperCon 2011 Page 1416

Overview

• Ashland and Michelman have partnered to develop water-based barrier systems (WBBS) for paper and paperboardbased barrier systems (WBBS) for paper and paperboard packaging

• A novel "base coat" for WBBS was recently developed and• A novel base coat for WBBS was recently developed and validated in several grades of paper and paperboard

• Improves water, oil and grease resistance and reduces moisture vapor transmission rate of WBBS

• Performs better and costs less than other technologies and offers a number of environmental benefits

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Trends Driving Development and Use of WBBS

Consumer Lifestyle Environmental Increasing Costs Consumer Safety

Fast Foods +Health Foods +

F h F d

Raw Material Costs: Oil, Wax, Aluminum,

Polyethylene + F i ht d

Increased Use of Renewable and

Recyclable Materials

Health Concerns:Mineral Oil, Wax,

Fl b PFOAFresh Foods Freight and Logistics Costs

Materials+ Compliance

DirectivesFluorocarbon, PFOA

Improved OGR Treatments +

Longer Shelf Life

Reduced Poly and Wax Coat Weights

and Aluminum Gauges

New Alternatives: WBBS and Bioplastics

New Alternatives:WBBS

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End Uses for WBBS

• Fast food containers

• Sandwich wraps

• Pizza boxes

• Corrugated packaging

• P d b• Produce boxes

• Poultry boxes

• Pet food bags

PaperCon 2011 Page 1419

Overview of Novel Base Coat for WBBS

• Ready-to-use product serves as a low-cost "primer" (2-4 g/m2)

• Applied at the size press or coater

• M difi d i th f t h f• Modifies and improves the surface topography of paper and paperboard without sealing

• Holds more expensive top coat at surface• Holds more expensive top coat at surface

• FDA-approved formulation is a patent pending combination of mineral binder and cationic crosslinkercombination of mineral, binder and cationic crosslinker

• Marketed as Dimension™ BC1060 converting additive

PaperCon 2011 Page 1420

Comparison of Untreated and Treated Sheets

Treated Sheet - Base CoatUntreated Sheet

Surface closure improves the performance of WBBS

Open surface allows water, oil and grease penetration

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Benefits of Novel Base Coat for WBBS

• Improved water, oil and grease resistance

• Reduced moisture vapor transmission

• Reduced cost of total barrier package• Reduced cost of total barrier package

• Reduces or replaces wax and polyethylene coatings

• Eliminates the use of fluorocarbons

• Allows for the increased use of renewable materials and improves the ease of recycling

PaperCon 2011 Page 1422

Base Coat* / Top Coat – OGR Data

8

10

6

8

it #

2

4

K

0

2

0 2 4 6 8 10 12

Base coat allowed a 53% reduction in top

Coat Weight (g/m2)

Michem® Coat 51 Dimension™ BC1060 pcoat weight!*Coater Applied

PaperCon 2011 Page 1423

Base Coat* / Top Coat – Cobb Data

25

302 )

20

25ob

b (g

/m2

10

15

Min

ute

Co

0

52-M

0 2 4 6 8 10 12Top Coat Weight (g/m2)

Mi h ® C t 51 Di i ™ BC1060*Coater Applied

Michem® Coat 51 Dimension™ BC1060

PaperCon 2011 Page 1424

Th k Y !Thank You!

PaperCon 2011 Page 1425