Sustainable Barrier Coatings in Paper and Board to 2023 - a State-of-the-Art Report

Technologies in the sustainable coatings for paper and board space in 2018 will proceed to grow to 2023 – including advanced aqueous polymeric solutions, such as polyvinyl alcohol (PVOH); advanced aqueous polymeric dispersions, thermoset resins; and polylactic acid (PLA).


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Product detail
Product type: Market report
Date of publication: 05 Nov 2018
Product format: Hard copy, Digital copy
Number of tables: 149
  • This market dominance is due to multiple factors – namely their cost-performance, relative ease of use, available global capacity, and range of product applications. These leading technologies are becoming the preferred option for the paper and paperboard industry. Continued investment in research is expected to lead to advances and the expanded use of most of the other technologies examined, specifically for applications based on polyhydroxyalkanoates (PHA/PHB) and nanocellulose composites. However, commercial considerations and competitive pressures will lead to declines in the use of technologies such as bio-PET, PBAt and thermoplastic starch (TMS) blends.


Our exclusive content:

  • Comprehensive scoring and ranking for the 20 most significant technologies that will impact the sustainable coatings market for paper and board to 2023.
  • Qualitative analysis of key drivers and application requirements, and their impact on technology evolution to 2023.
  • A comprehensive examination of key technologies in the sustainable coatings for paper and board space to 2023.

What methodology is used?

Sustainable Barrier Coatings in Paper and Board to 2023 – a State-of-the-art Report is based on a combination of in-depth primary and secondary research. Primary research included refinement of Smithers Pira’s databases on paper and board throughout the world, and a wide-ranging survey of stakeholders in the coatings and paper and board industries. An expert panel provided insights to help develop a shortlist of the top 20 technologies in sustainable coatings for paper and board, and to define scores and a ranking for each of the 20 technologies analysed.

This exclusive content was contextualized and integrated with secondary research drawn from third-party databases and historical data – including official statistics, trade associations, trade directories, market reports, journals, websites, and industry contacts – and detailed analyses of economic data.

What will you discover?

  • An analysis of the future requirements for and capabilities of sustainable coatings on paper and board to 2023.
  • An exclusive and comprehensive scoring and ranking of the 20 most significant technologies forecast to impact the sustainable coatings for paper and board market over the forecast period.
  • In-depth analysis of the current state-of-the-art for each technology, key technology challenges and a forecast for future commercialisation.

Who should buy this report?

  • Raw material suppliers
  • Coating product manufacturers
  • Substrate suppliers
  • Packaging converters and printers
  • Brand owners and retailers
  • Industry consultants and analysts 

table of contents

Executive Summary. 2

0.1 Background. 3

0.2   Dominant Trends. 5

0.3 Opportunities. 6

0.4  Technology Rankings. 7

1.0 Report Scope. 11

1.1. Report Objective. 11

1.1.1 Methodology. 11

1.1.2 Secondary Research. 12

1.1.3 Survey Data. 12

1.1.4 Rankings. 13

1.1.4 Primary Research Interviews. 13

1.2. Technology Challenges. 13

1.3. Glossary of Terms. 14

1.4. Acronyms and Abbreviations. 19

1.5. Sustainability Organizations. 20

2.0 Sustainable barriers for paper and board: Current and future requirements. 22

2.1.       Where and how barrier coatings are used for paper and board. 22

2.2.       Sustainability and environmental pressures on paper and board companies and users. 31

2.3.       Current regulatory landscape for paper and board use. 32

2.4.       Sustainable barriers as a development area. 36

2.5.       Market opportunities for sustainable barrier coatings, or other innovative sustainable barrier solutions. 40

Chapter 3. 42

3.1.  Nanocellulose Films. 49

3.1.1 Technology Overview.. 49

3.1.2 State-of-the-art Developments. 49

3.1.3 Commercialisation Forecast. 51

3.1.4 Application Potential 52

3.2.  Nanofibrillated Cellulose (NFC) for Improved Properties. 55

3.2.1 Technology Overview.. 55

3.2.2  State-of-the-art Developments. 55

3.2.3  Commercialisation Forecast. 56

3.2.4 Application Potential 57

3.3.  Nanocellulose Composites. 60

3.3.1  Technology Overview.. 60

3.3.2  State-of-the-art Developments. 61

3.3.3  Commercialisation Forecast. 62

3.3.4  Application Potential 63

3.4.  Biodegradable Bio-based Polymer Films: Chitosan. 65

3.4.1  Technology Overview.. 65

3.4.2  State-of-the-art Developments. 66

3.4.3  Commercialisation Forecast. 67

3.4.4  Application Potential 67

3.5.  Biodegradable Bio-based Polymer Films: Alginates. 71

3.5.1  Technology Overview.. 71

3.5.2   State-of-the-art Developments. 72

3.5.3  Commercialisation Forecast. 72

3.5.4  Application Potential 73

3.6.  Biodegradable Bio-based Polymer Films: Lignin-Derived Thermoplastic Barriers. 76

3.6.1  Technology Overview.. 76

3.6.2  State-of-the-art Developments. 78

3.6.3   Commercialisation Forecast. 79

3.6.4  Application Potential 80

3.7.  Polymer-Pigment Composites. 83

3.7.1  Technology Overview.. 83

3.7.2  State-of-the-art Developments. 85

3.7.3  Commercialisation Forecast. 87

3.7.4  Application Potential 87

3.8.  Chemical Vapor Deposition: SiOx. 90

3.8.1  Technology Overview.. 90

3.8.2 State-of-the-art Developments. 91

3.8.3  Commercialisation Forecast. 92

3.8.4  Application Potential 93

3.9.  Diamond-Like Carbon (DLC) Coatings. 95

3.9.1  Technology Overview.. 95

3.9.2  State-of-the-art Developments. 96

3.9.3  Commercialisation Forecast. 97

3.9.4  Application Potential 97

3.10.  Functionalized Cellulose. 99

3.10.1  Technology Overview.. 99

3.10.2  State-of-the-art Developments. 100

3.10.3  Commercialisation Forecast. 101

3.10.4  Application Potential 102

3.11.  Protein-based Barrier Coatings: Zein Protein. 104

3.11.1  Technology Overview.. 104

3.11.2  State-of-the-art Developments. 105

3.11.3  Commercialisation Forecast. 106

3.11.4  Application Potential 106

3.12.         Advanced Aqueous Polymeric Solutions: PVOH.. 108

3.12.1    Technology. 108

3.12.2 State-of-the-art Developments. 109

3.12.3 Commercialisation Forecast. 110

3.12.4 Application Potential 111

3.13.         Advanced Aqueous Polymeric (Resin) Dispersions. 113

3.13.1    Technology. 113

3.13.2 State-of-the-art Developments. 115

3.13.3 Commercialisation Forecast. 116

3.13.4 Application Potential 116

3.14.         Biodegradable Bio-based Aliphatic Polyesters: PLA.. 118

3.14.1    Technology. 118

3.14.2 State-of-the-art Developments. 120

3.14.3 Commercialisation Forecast. 120

3.14.4 Application Potential 122

3.15.         Biodegradable Microbial Polyesters: PHA.. 124

3.15.1    Technology. 124

3.15.2 State-of-the-art Developments. 126

3.15.3 Commercialisation Forecast. 126

3.15.4 Application Potential 127

3.16.         Biodegradable Bio-based Aliphatic Polyesters: PBS. 129

3.16.1    Technology. 129

3.16.2 State-of-the-art Developments. 130

3.16.3 Commercialisation Forecast. 131

3.16.4 Application Potential 132

3.17.         Biodegradable Bio-based Aromatic Polyesters: PEF. 135

3.17.1    Technology. 135

3.17.2 State-of-the-art Developments. 137

3.17.3 Commercialisation Forecast. 137

3.17.4 Application Potential 138

3.18.         Bio-based Polyesters (bio-PET, PBAt). 140

3.18.1    Technology. 140

3.18.2 State-of-the-art Developments. 141

3.18.3 Commercialisation Forecast. 142

3.18.4 Application Potential 143

3.19.         Thermoplastic Starch. 145

3.19.1    Technology. 145

3.19.2 State-of-the-art Developments. 147

3.19.3 Commercialisation Forecast. 148

3.19.4 Application Potential 149

3.20.         Nanosilicate Composites. 151

3.20.1    Technology. 151

3.20.2 State-of-the-art Developments. 153

3.20.3 Commercialisation Forecast. 154

3.20.4 Application Potential 155

References. 157

tables and figures

  • Technology categories with corresponding application methods, as well as the specific barrier technologies examined within this report
  • Top 20 sustainable barrier technologies for paper and paperboard in 2018
  • Top 20 sustainable barrier technologies for paper and paperboard in 2023
  • Glossary of terms
  • Acronyms and abbreviations
  • Sustainability organisations
  • Barrier packaging paper and paperboard products
  • Typical barrier coatings for paper and paperboard, along with examples and application methods
  • Developers of sustainable barrier coatings and their ingredients
  • Key players in paper and paperboard product supply
  • Regulatory initiatives affecting paper and paperboard
  • Compostability standards in major markets
  • Leading compostability certification organisations
  • Life cycle analysis tools
  • The process of manufacturing a paper cup
  • Common barrier coating materials that are being considerable as sustainable barrier materials for paper and paperboard applications
  • Bio-based barrier coating technologies, their degree of market readiness, and degree of bio-degradability
  • Common bio-based polymers used in the paper lamination, beverage & coffee cups, and foodservice packaging, along with their performance factors, advantages, and disadvantages
  • Comparative performance of curtain versus extrusion coating process technologies
  • Comparison of commercial coating methods used for barrier paper and paperboard
  • Leading nanocellulose manufacturers
  • SWOT analysis: nanocellulose films
  • Nanocellulose films: scorecard
  • Nanocellulose films: status
  • Nanocellulose films: application opportunities and forecast
  • SWOT analysis: NFC for improved properties
  • Nanofibrillated cellulose: scorecard
  • Nanofibrillated cellulose: status
  • Nanofibrillated cellulose: application opportunities and forecast
  • SWOT analysis: nanocellulose composites
  • Nanocellulose composites: scorecard
  • Nanocellulose composites: status
  • Nanocellulose composites: application opportunities and forecast
  • SWOT analysis: chitosan
  • Leading suppliers of chitosan
  • Chitosan: scorecard
  • Chitosan: status
  • Chitosan: application opportunities and forecast
  • SWOT analysis: alginates
  • Alginates: scorecard
  • Alginates: status
  • Alginates: application opportunities and forecast
  • Leading manufacturers of sulfite and kraft lignin
  • SWOT analysis: lignin
  • Lignin-derived thermoplastics: scorecard
  • Lignin-derived thermoplastics: status
  • Lignin-derived thermoplastics: application opportunities and forecast
  • List of common pigment types (platy and non-platy) and polymer chemistries used in the production of polymer-pigment composites
  • List of leading mineral supplier companies to the paper and paperboard industry, along with mineral types and brand names used in barrier applications
  • SWOT analysis: polymer-pigment composites
  • Polymer-pigment composites: scorecard
  • Polymer-pigment composites: status
  • Polymer-pigment composites: application opportunities and forecast
  • SWOT analysis: SiOx
  • Chemical vapour deposition: scorecard
  • Chemical vapour deposition: status
  • Chemical vapour deposition: application opportunities and forecast
  • SWOT analysis: diamond-like coatings
  • Diamond-like coatings: scorecard
  • Diamond-like coatings: status
  • Diamond-like coatings: application opportunities and forecast
  • SWOT analysis: functionalized cellulose
  • Functionalised cellulose: scorecard
  • Functionalised cellulose: status
  • Functionalised cellulose: application opportunities and forecast
  • SWOT analysis: zein protein
  • Protein-based barrier coatings: scorecard
  • Protein-based barrier coatings: status
  • Protein-based barrier coatings: application opportunities and forecast
  • Comparative barrier performance of PVOH
  • Producers of PVOH/EVOH for packaging applications
  • SWOT analysis: PVOH/EVOH
  • Advanced aqueous polymeric solutions: scorecard
  • Advanced aqueous polymeric solutions: status
  • Advanced aqueous polymeric solutions: application opportunities and forecast
  • Emulsion polymer and water-based coating producers for barrier applications
  • SWOT analysis: emulsion and resin dispersions
  • Advanced aqueous polymeric (resin) dispersions: scorecard
  • Advanced aqueous polymeric (resin) dispersions: status
  • Advanced aqueous polymeric (resin) dispersions: application opportunities and forecast
  • Mechanical properties of PLA and selected fossil-based polymers
  • Leading manufacturers of PLA and associated brand names
  • SWOT analysis: polylactic acid
  • Polylactic acid: scorecard
  • Polylactic acid: status
  • Polylactic acid: application opportunities and forecast
  • Comparison of physical properties of PHB and PHB-V with other bio-based polymers and petroleum-derived polymers: HDPE, Ecofle, and PP
  • Leading PHA, PHB, and PHBV producers
  • SWOT analysis: PHA/PHB
  • Polyhydroxyalkanoates (PHA/PHB): scorecard
  • Polyhydroxyalkanoates (PHA/PHB): status
  • Polyhydroxyalkanoates (PHA/PHB): application opportunities and forecast
  • Comparative mechanical properties of relevant polymers (typical values)
  • Comparative properties of biopolymers
  • Worldwide PBS producers
  • SWOT analysis: polybutylene succinate (PBS)
  • Polybutylene succinate (PBS): scorecard
  • Polybutylene succinate (PBS): status
  • Polybutylene succinate (PBS): application opportunities and forecast
  • Comparative properties of PEF with PET and potential applications from Corbion Purac
  • PEF manufacturing potentials and innovators
  • SWOT analysis: polyethylene furanoate (PEF)
  • Polyethylene furanoate (PEF): scorecard
  • Polyethylene furanoate (PEF): status
  • Polyethylene furanoate (PEF): application opportunities and forecast
  • Global PBAt producers
  • Major global players in bio-PET
  • SWOT analysis: bio-based polyesters (PET/PBAt)
  • Bio-based polyesters (PET, PBAt): scorecard
  • Bio-based polyesters (PET, PBAt): status
  • Bio-based polyesters (PET, PBAt): application opportunities and forecast
  • Leading manufacturers of starch and starch blends
  • SWOT analysis: starch and starch blends
  • Thermoplastic starch: scorecard
  • Thermoplastic starch: status
  • Thermoplastic starch: application opportunities and forecast
  • Various clay types and exfoliating treatments, along with polymer additives
  • Producers of nanoclays used in WBBC and polymer composites for packaging
  • SWOT analysis: nanoclays/nanosilicates
  • Nanosilicate composites: scorecard
  • Nanosilicate composites: status
  • Nanosilicate composites: application opportunities and forecast
  • An overview of the sustainable barrier coating value chain in the paper and paperboard industry, showing essential (grey) and optional value chain elements (in white)
  • Overview of report methodology
  • Breakdown of survey respondents by affiliation and representation
  • Coated one-side (C1S) and coated two-side (C2S) paper and paperboard construction showing the basepaper and typical coating layers
  • Multi-ply barrier board construction showing various coating layers
  • Process steps used to produce a barrier-coated paper or paperboard product
  • The sustainable barrier coating value chain
  • SWOT analysis for coating suppliers to the barrier paper and paperboard market
  • Cradle-to-factory-gate energy consumption for barrier materials showing contributions from the feedstock and the process
  • Common barrier coating materials that are being considerable as sustainable barrier materials for paper and paperboard applications
  • The impact of nanocellulose on barrier performance depicting the diffusion of a gas molecule across the barrier with and without nanoparticles
  • Chemical structures of chitin, chitosan, alginate and cellulose
  • The chemical structure of lignin sub-units: guaiacyl (R1=OCH3, R2=H); syringyl (R1=R2=OCH3), and p-coumaryl (R1=R2=H)
  • Ratio of guaiacyl (G) to syringyl (S) in biomass
  • Tetra-Laval’s barrier board concept that uses a lignin-based barrier coating to increase resistance to oxygen transmission and improve moisture resistance
  • Platy pigment showing dimensions of length (L) and thickness (D)
  • Typical plasma deposition machine showing key components
  • Relationship between hybridisation scheme and structure in hydrocarbon structures
  • Summary of TEMPO-mediated oxidation of cellulose
  • Unfolding of zein protein using a surfactant
  • The chemical structure of PVOH
  • Process steps used in the application of dispersion coatings on paper and paperboard
  • Overview of PHA production and extraction process
  • The production of  polyethylene furanoate (PEF) from 2,5-furandicarboxlic acid (FDCA) and ethylene glycol
  • Overview of the YXY production pathway for PEF showing targeted end uses
  • Chemical structure of starch showing the amylase (linear) and amylopectin (branched) morphologies
  • Preparation of nanoclays from an aqueous solution of ammonium chloride