In the current business environment, sustainability is no longer merely nice to have as its imperative. There is growing pressure on businesses to reduce plastic consumption, minimize overall carbon footprints, and align practices with developing consumer expectations for environmentally focused practices and at the same time produce high quality packaging performance. One innovation that is helping to address this gap is barrier coated paper, a multi use, environmentally friendly replacement to traditional plastics that combines durability, functionality, and sustainability.
Barrier coated papers offer multi functional protection against moisture, greases, and oils in food service, retail, and e-commerce applications, while also being compostable, repulpable and recyclable, which benefits those focusing on performance & environmental stewardship.
Benefits of Barrier Coated Paper
Barrier coated paper combines the functional advantages of coatings with the ecology of fibers.
1. Functionality and Protection
- Offers resistance to moisture, grease, and oils to help maintain the freshness and quality of food and other sensitive products.
- Increases shelf life through a reduction of oxygen and moisture infiltration, as measured by key performance indicators of OTR (Oxygen Transmission Rate) and WVTR (Water Vapor Transmission Rate).
- Works with hot, cold, or liquid products; as well as food carry out containers, retail packaged items, and shipping.
2. Environmentally Sustainable
- Produced from responsibly sourced fibers.
- Repulpable and compostable, reducing landfill waste.
- Contributes to a circular economy by repurposing single use plastic with recyclable products.
3. Brand Value
- Eco friendly consumers are loyal to companies that demonstrate sustainability in their packaging.
- Barrier coated paper can create brand equity and a favorable reputation.
Technical Insights: Why Barrier Coatings Matter
Barrier coated paper is more than just “eco friendly paper.” The coating type and design impact packaging performance , recyclability, and cost.
Key Barrier Metrics:
Application | Desired OTR | Desired WVTR | Purpose |
Dry snacks (chips, crackers) | Low | Very low (<10 g/m²·day) | Maintain crispness, prevent moisture |
Greasy foods (fast food wraps, takeout) | Low | Low WVTR + oil resistance | Prevent sogginess or grease seepage |
Frozen/refrigerated foods | Moderate | Low WVTR | Avoid condensation or freezer damage |
Water Based vs. Solvent Based Coatings:
- Water based coatings : Eco friendly, biodegradable, easier to recycle.
- Solvent based coatings : Higher barrier performance, but often less sustainable and harder to repulp.
- Tradeoffs : More layers or thicker coatings improve barriers but can increase costs, reduce recyclability, and require precise manufacturing control.
Applications Across Industry
1. Food Packaging
- Sandwich wraps, bakery boxes, take out containers, and coffee cup sleeves.
- Preserves product integrity with safety for food contact.
2. Retail & Gift Packaging
- Protects the product from moisture or handling damage.
- Convey an environmentally sustainable brand message to customers.
3. Shipping & Logistics
- Mailers, cartons, pallet wraps, or interior protective packaging.
- Repulp or recycled papers keep plastic films out of the waste stream while protecting shipments.
Compliance and safety standards
Compliance with the relevant compliance standards is especially important for food contact applications.
Country and International Regulation Standards:
- FSSAI Food Safety & Standards Authority of India: the FSSAI standards mandate that all paper and coatings must be pinhole free, speck free, grease mark free, and suitable for direct food contact.
- IS standards: IS standards establish specifications for greaseproof paper, folding box paper, and parchment paper.
- International: EU and US regulations specify limits on migration for coatings, inks, and additives.
Best Practice Considerations for Manufacturers and Brands
1. Use materials that are food grade and suitable for food contact.
2. Test or evaluate uniformity, thickness, and adhesion of the coating.
3. Performing migration and safety tests through a NABL accredited laboratory.
4. Monitor updates in BIS draft standards and upcoming regulations.
Costs & Environmental Trade Offs
Water based barrier coated papers may have a higher initial cost than plastic options but provide long lasting advantages such as:
- Lower product spoilage or product returns.
- Reduced compliance costs (fines, recalls).
- A higher perceived value for the brand and customer loyalty.
- Better recyclability and lower environmental footprint.
In many cases, using a life cycle approach indicates that barrier coated paper is a cost effective option after factoring in environmental and performance aspects.
Examples from the real world are
- Food Chains: Transitioning to entirely compostable paper wrappers with barrier coatings mitigated packaging waste while allowing product integrity.
- Retail: Using coated paper gift boxes preserved the product from moisture damage and appealed to an eco conscious clientele.
- E commerce: Using repulpable paper for substrate inserts and subscription boxes offered product protection without any sacrifice to recyclability.
Frequently Asked Questions
Q1: Is biodegradable paper durable enough for shipping?
Yes. Proper barrier coatings provide strength and moisture resistance suitable for safe shipment.
Q2: Is barrier coated paper recyclable?
Yes. Many barrier coated papers are fully recyclable or repulpable, depending on coating materials.
Q3: How does compostable packaging work?
Compostable papers naturally break down in composting conditions into nutrient rich material, reducing landfill impact.
Q4: Are eco-friendly papers safe for food contact?
Yes. They meet industry standards for hygiene, grease, and moisture resistance.
Q5: Do sustainable papers improve brand image?
Absolutely. Eco conscious packaging attracts environmentally aware consumers and strengthens reputation.
Conclusion: A Path Toward Sustainability
Barrier coated paper is a great combination of performance, safety and sustainability. By identifying barrier properties, types of coatings, regulatory requirements and how to evaluate life cycle costs, end users of barrier coated paper can consider packaging solutions that provide product protection, efficacy and consumer satisfaction, while also reducing the impact on the environment.
Take the Next Step
To discover how barrier coated paper can improve your packaging and still be sustainable in packaging compliance, contact Evergreen Sustainable today. Our expert team will work with you to identify materials, test materials, evaluate applications, and develop innovative and safer packaging solutions.