What Is Water-Based Barrier Coating?
Water-based barrier coating is a PFAS-free technology that uses aqueous dispersions of polymers to create a protective layer on paper and paperboard. Unlike solvent-based or extrusion-coated alternatives, water-based coatings are applied as a liquid dispersion and dried to form a continuous film that blocks moisture, oxygen and grease.
This technology has become the leading alternative to PE extrusion coating and PFAS-containing treatments in food packaging applications, driven by regulatory pressure on single-use plastics and persistent chemicals.
How Water-Based Coating Works
The coating formulation consists of polymer particles suspended in water. When applied to the paper surface and dried, the particles coalesce to form a uniform barrier film. Key coating methods include:
- Rod coating: Precision control of coating weight, ideal for uniform barrier layers
- Blade coating: High-speed application for large-volume production
- Spray coating: Suitable for complex shapes and selective coating areas
- Size press coating: Integrated into paper machine for inline processing
Environmental Benefits Comparison
| Property | Water-Based Coating | PE Extrusion | PFAS Treatment |
|---|---|---|---|
| PFAS-Free | ✓ | ✓ | ✗ |
| Recyclable (paper stream) | ✓ | ✗ | ✓ |
| Industrial Compostable | Depends | ✗ | ✗ |
| Repulpable | ✓ | ✗ | ✓ |
| VOC-Free | ✓ | ✓ | ✓ |
Key Performance Metrics
- Kit grade: 6-12 (3M Kit test), customizable per application
- Cobb value: <20 g/m² (60s), indicating excellent moisture resistance
- Heat seal temperature: 120-180°C, compatible with high-speed packaging lines
- Coating weight: 3-20 gsm, single or double side
- Temperature resistance: Up to 200°C for hot-fill and microwave applications
Applications
Paper Cups and Cupstock
Water-based coated cupstock board replaces traditional PE-coated cups for both hot and cold beverages. The coating provides leak-proof performance while allowing the paper to be recycled in standard paper streams. View Water-Based Cupstock →
Food Containers and Lunch Boxes
For takeaway containers and food service board, water-based coatings deliver oil and moisture resistance while maintaining foldability and die-cutting performance. View Food Service Board →
Burger Wrappers and Fast Food Packaging
Water-based coated papers provide grease resistance for burger wrappers, sandwich wraps and fast food packaging without relying on PFAS chemicals. View Burger Wrappers →
Kraft Wrapping Paper
Both bleached and unbleached kraft papers can be water-based coated for eco-friendly brand packaging, offering a natural look with barrier performance. View Coated Kraft Paper →
Compliance and Certifications
- FDA 21 CFR 176.170 and 176.180 for food contact
- EU Regulation EC 1935/2004 and 10/2011
- BRC-certified production facilities
- Repulpable and recyclable per PTS and other industry standards
FAQ
Is water-based coating safe for food contact?
Yes. Water-based barrier coatings are formulated with FDA and EU food contact compliant materials. They do not contain PFAS, PVDC or other restricted substances.
Can water-based coated paper be recycled?
Yes. Unlike PE-coated papers, water-based barrier coatings allow the paper to be repulped and recycled in standard paper recycling streams.
What is the shelf life of water-based coated paper?
With proper storage, water-based coated papers maintain their barrier properties for 12-24 months.
How does water-based coating compare to PLA coating?
Water-based coatings offer better heat sealability and recyclability, while PLA coatings are renewable and industrially compostable.
Can I get samples for testing?
Yes. Contact us to request samples of our water-based coated papers for your specific application testing.