Open Innovation Submission Portal

Moisture barrier for paper substrate - Flexible Packaging

Request Number 220441 | Author PepsiCo

Description

We have been working on paper base structures as a potential option for our flexible food packaging to help with our sustainability goals of having 100% RCB compliance for our packages by 2030.

While flexible package is a very sustainable option from a material use point of view, the multi-layer multi-material structures are not conducive for recycling and mostly end up in the landfill or as litter. Paper helps us with the end of life issues and can be recyclable, biodegradable and compostable.

Maintaining packaging performance such as shelf stability, oxygen and moisture barrier are a must on this project.

Oxygen barrier is not a problem with current technologies available but achieving the very high moisture barrier required for packaging dry foods has been a challenge.

We understand that new technologies will be needed to achieve the high moisture barrier requirements (< 0.3 g/m2/day under Tropical conditions). Also, it is important to maintain this barrier under forming conditions in the VFFS process of bag-making. We are looking for novel solutions that can be added to the paper, if possible, as a high functional coating applied through flexographic or rotogravure process and/or a skin layer with high functionality that can anchor metal (metallization).

The functional layer/coating must be compliant with paper recycling process and biodegradable/compostable.

Key Success Criteria

Must-Haves

  • The functional barrier layer/coatings should be able to be applied through commercially available Flexo or Rotogravure process;
  • It must be FDA approved for primary food packaging;
  • It must be compliant with paper recycling process and be biodegradable/ home compostable;
  • If metallization is considered in combination with the functional barrier layer/coating, it should be applicable to the paper by commercially available processes;
  • Should consider standard food grade white recyclable coated paper as the substrate to receive the functional barrier layer/coatings;

Nice-Haves

  • Solvent-free coating technology is ideal from a GHG point of view but willing to try both water-based and even solvent-based technologies
  • Recent advances in metallization with other metals like silicon etc. are welcome
  • Improve paper puncture resistance to the paper substrate;
  • Sealing properties added to the functional barrier layer;
  • Grease barrier added to the functional barrier layer;
Approaches not of interest

Technologies that have been previously investigated would only have interest if a significant advancement has been made beyond PepsiCo's knowledge.

  • Commercially available coated paper with some barrier from paper industry
  • Nano-cellulose coatings but recent advances are very welcome
Preferred Collaboration types

We are open to the following types of engagement:

  • sponsored research for development and proof of concept testing, consultation, licensing existing technology for PEP to apply, purchase commercial ready solution, open to any, etc.).