Simplifying the Complex

Digital print and finishing technologies offer countless benefits to the print landscape. However, there are complexities, such as unique, short-run jobs that have little to no room for error. Equipment manufacturers, software and workflow vendors, and integrators work together to ensure seamless and profitable production across digital application range.

Equipment manufacturers, software and workflow vendors, and integrators work together to ensure seamless and profitable production across the digital application range.

The use of digital printing and finishing tools for label production is growing. One essential part of the puzzle for making the economics work is automation and workflow. We address the availability of software and workflow tools that help streamline digital and hybrid label production environments in Streamlining Label Production

While labels and packaging are hot markets, transactional documents still make up a significant amount of overall printed pages. We discuss how electronic distribution and inkjet have revolutionized this market in Transactional Evolution

Our Best Practices column looks at barrier coatings and papers for flexible packaging. These are increasingly designed to support environmental initiatives in demand by end customers.

Our next issue will feature our semi-annual Label and Packaging Application of the Year awards. We’re teaming up with our sister publication, Industrial Print magazine on this and are looking to spotlight exceptional label and packaging pieces created by our readers. Check out dpsmagazine.com for more information!

Additionally, visit dpsmagazine.com/webinars for webinars on transactional printing and label workflow.

Best regards, Cassandra Balentine, editor

cbalentine@rockportpubs.com

dpsmagazine.com

Volume 25, Number 3 • ISSN: 1529-2320

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Seal and Protect

Barrier Coatings and Papers Evolve for Flexible Packaging

By Cassandra Balentine

Specially formulated coatings and papers present a physical barrier between a product and packaging to protect against moisture and grease. These are increasingly developed to be more sustainable without compromising safety.

Papers Versus Coatings

There are a few differences between barrier coatings and barrier papers for flexible packaging.

“The main difference is that barrier paper typically refers to papers formulated with barrier properties against moisture and grease. This is usually done at the paper mill level during the paper manufacturing stage,” explains Mark Hill, SVP, R&D, INX International Ink Co.

On the other hand, “barrier coatings are typically applied to a substrate after it is manufactured and provides properties like moisture, oxygen, or grease resistance to the substrate,” he adds.

Perla Johnson, marketing and product manager, S-One Holdings Corporation, points out that a barrier paper already has inherent barrier properties, while barrier coatings can be applied to paper, film, board, or other substrates.

A coating is one way to create a barrier paper, says Dr. Lars Hancke, manager, business development, flexible packaging, hubergroup. He explains that another option is to create a barrier with the help of a film. “Barrier coatings can, for example, also be used to create monomaterial plastic packaging that can be recycled more easily.”

Barrier paper is specifically designed to provide barrier performance as part of its structure. “Barriers to grease and oil, oxygen, and liquid water can be built into the paper manufacturing process. Barrier coatings can be used in conjunction with barrier papers to further increase performance and enable additional barriers to moisture,” comments Zack Leimkuehler, VP, business development, Ahlstrom.

Target Industries

Food packaging is the primary market for barrier coatings and papers.

Barrier coatings can be used in conjunction with barrier papers to further increase performance and enable additional barriers to moisture.

— Zack Leimkuehler, VP, business development, Ahlstrom

This is because food and other industrial packaging materials are sensitive to oxygen and moisture.

“The main reason is to prolong shelf life and withstand certain storage conditions,” says Hill.

Cristal Transparent packaging providers natural barrier properties while also creating a view to the product it protects. 2. Michelman, in conjunction with Bobst and UPM, developed new coating technologies designed to match the high barrier performance of today’s multi-material laminations.

“Barrier papers with a heat seal layer target flexible packaging converters. Most foods need a barrier to keep the contents fresh within the package. The barrier offers extended shelf life,” notes Johnson.

Barrier papers are gaining importance in packaging due to a trend from film to more sustainable paper packaging, shares Hancke.

Leimkuehler points out that there are many different industries where a barrier technology is desired. “These can be barriers to regulated materials like formaldehyde or mineral oil, where the paper is key in protecting the material from transferring into or out of the structure. One of the primary targets is in the flexible packaging space where paper can offer better sustainability than historically used fossil-based films or where compostability or recyclability is desired.”

Barrier papers and/or coatings are prevalent in many printed applications as they serve as the primary brand communication in packaging materials, including digital print spaces.

Leimkuehler adds that barrier papers can be used in a variety of printed applications, and the entire supply chain is important in the development of these applications. “Packaging converters play a critical role in converting the final packaging material from barrier papers.”

Barrier Papers/Coatings

Barrier papers are a core component in many flexible packaging applications today, and are growing in market share due to the preference for a more sustainable solution as opposed to fossil-based films and plastics.

“Some common examples of how barrier papers are used in flexible packaging include non-perishable food packaging, perishable food packaging including refrigerated/frozen foods, and packaging that requires longer shelf life such as microwave packaging,” shares Leimkuehler.

The primary component of all barrier papers is cellulose. Leimkuehler explains that cellulose is a natural polymer, which is an ideal raw material from a sustainable standpoint. It is readily recyclable and compostable, and there are already high recycling rates for cellulose-based papers.

Other raw materials include a variety of additives that contribute to the technical performance of the material, and help papermakers tailor solutions specifically for their end use and end of life.

Johnson says they can be made from high-quality Kraft paper on the exterior with a heat-sealable layer on the inside.