The use of disposable cups has become a major concern for the environment due to their negative impact on nature. In response, many companies have started using eco-friendly options to reduce their carbon footprint. One such alternative is water-based barrier coated paper cups, which are a more sustainable option than traditional plastic cups. This article aims to provide a detailed overview of water-based barrier coated paper cups, including their composition, advantages, manufacturing process, and environmental impact.
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Water-based barrier coated paper cups are made of paperboard, which is coated with a thin layer of a water-based coating material. This coating material is made of natural minerals and polymers, which creates a barrier between the paperboard and the liquid, making it resistant to moisture and liquid. The coating material used in these cups is free from harmful chemicals such as perfluorooctanoic acid (PFOA) and perfluorooctane sulfonate (PFOS), making it safe for human consumption.
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Water-based barrier coated paper cups are designed to resist moisture and liquid, making them an ideal choice for holding hot and cold beverages. The coating on the cups creates a barrier between the paper and the liquid, preventing the paper from getting soaked and losing its structural integrity. This means that the cups will not become soggy or leak, making them more reliable than traditional paper cups.
Water-based barrier coated paper cups are more environmentally friendly than plastic cups. They are made from renewable resources and are biodegradable. This means that they can be composted, reducing waste and the environmental impact of disposable packaging.
Water-based barrier coated paper cups are cost-effective, making them an affordable alternative to plastic cups. They are also lightweight, which makes them easier and cheaper to transport than heavier plastic cups.
Water-based barrier coated paper cups can be customized with logos, images, and text, making them an effective marketing tool. This is a significant advantage for businesses that want to promote their brand and create brand recognition.
Water-based barrier coated paper cups are food safe and do not contain any harmful chemicals that can leach into the beverage. This makes them a safe option for consumers.
Water-based barrier coated paper cups have limited heat resistance, making them unsuitable for extremely hot beverages >100 degrees. This is because the coating on the cups can break down when exposed to high temperatures, making the cups less effective at resisting moisture and liquid.
Water-based barrier coated paper cups have a limited shelf life, making them unsuitable for long-term storage. The coating on the cups can break down over time, reducing their effectiveness at resisting moisture and liquid. This means that businesses need to be careful when ordering water-based barrier coated paper cups, ensuring that they do not order more than they need.
Water-based barrier coated paper cups are not yet as widely available as plastic cups, which may limit their use in some areas. However, as more businesses become aware of the benefits of water-based barrier coated paper cups, this is likely to change.
The manufacturing process of water-based barrier coated paper cups involves several stages, including
The first stage of manufacturing water-based barrier coated paper cups is paperboard production. Paperboard is a type of thick paper used for packaging. It is made from wood pulp and is thicker and more durable than regular paper.
Once the paper board is produced, it is coated with a thin layer of the water-based barrier coating material. This is done using a coating machine, which applies the coating material evenly across the surface of the paperboard. The coating machine is designed to ensure that the coating material is applied in the right amount, ensuring that the cups are resistant to moisture and liquid.
Once the paperboard is coated, it is cut into sheets and formed into cups using a cup forming machine. The cup forming machine uses a series of rollers and molds to shape the paperboard into cups. The cups are then glued together at the seams to ensure that they are watertight.
Once the cups are formed, they can be printed with logos, images, and text. This is done using a printing machine, which applies ink to the surface of the cups. The printing machine is designed to ensure that the ink is applied evenly and that the design is clear and legible.
Once the cups are printed, they are packaged and shipped to businesses for use. The packaging process involves placing the cups in stacks and then wrapping them in plastic or cardboard to protect them during transport.
BARRIER EFFECTS
Depending on the product, barrier coatings build up an adequate barrier effect against:
Coatings are available both for the interior and exterior use.
A SELECTION OF END USES
COATING PROPERTIES
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Depending on the product, our barrier coatings show further valuable characteristics:
PROCESSING
There are barrier coatings available for various processes. This includes:
Water-based barrier coated paper cups have a lower environmental impact than traditional plastic cups. They are made from renewable resources and are biodegradable, which means that they can be composted and will not contribute to landfill waste. In addition, the water-based coating material used in these cups is free from harmful chemicals, making them safe for human consumption.
However, the production of water-based barrier coated paper cups does have some environmental impact. The production process requires energy and water, which can contribute to carbon emissions and water pollution. In addition, the transportation of these cups requires fuel, which can contribute to air pollution and greenhouse gas emissions.
To minimize the environmental impact of water-based barrier coated paper cups, businesses can take several steps, including
Businesses can use renewable energy sources such as solar, wind, or hydroelectric power to reduce their carbon footprint. This can help to offset the energy used in the production and transportation of water-based barrier coated paper cups.
Businesses can reduce their water use by implementing water-saving measures such as recycling water, using low-flow faucets, and repairing leaks. This can help to reduce the water used in the production of water-based barrier coated paper cups.
Businesses can recycle water-based barrier coated paper cups, reducing the amount of waste that ends up in landfills. This can be done by separating the cups from other waste and placing them in a compost bin.
Businesses can reduce the environmental impact of transportation by sourcing water-based barrier coated paper cups from local suppliers. This can reduce the amount of fuel used in transportation and lower the carbon footprint of the cups.
Water-based barrier coated paper cups are a more sustainable alternative to traditional plastic cups. They are made from renewable resources, are biodegradable, and do not contain harmful chemicals. They are also customizable, cost-effective, and food safe. However, they have limited heat resistance and shelf life, and their production does have some environmental impact.
To minimize the environmental impact of water-based barrier coated paper cups, businesses can take steps such as using renewable energy, reducing water use, recycling, and sourcing cups from local suppliers. With increasing awareness of the benefits of eco-friendly options, it is likely that the use of water-based barrier coated paper cups will continue to grow in popularity, contributing to a more sustainable future.
FennoGuard GO is an innovative barrier solution that enables the development of fully recyclable and repulpable paper and board packaging. The dispersion barrier coating helps to reduce and replace plastics, e.g. Polyethylene (PE) extrusions, used in fiber-based packaging to create needed resistance against oil and grease, moisture, or other substances.
FennoGuard GO provides excellent oil and grease barrier properties and tailored water vapor resistance, and it is mainly intended for food service board and flexible packaging paper. Typical use case for paper or board that is treated with FennoGuard GO are take away food and fresh bakery products. In these cases, the packaging needs to provide good protection against grease and an optimized vapor resistance. Another example of a demanding end use is packaging for greasy pet food, which requires superior oil and grease barrier and long shelf life.
The compostability and repulpability of fiber-based material that is treated with FennoGuard GO have been proven in a series of tests. The dispersion barrier coating disintegrates in compost and breaks down in the repulping process, which makes the material easy to recycle. However, the base material has an impact on the end-product’s end of life properties, which means that each end-product needs to be tested for compostability and repulpability individually.
It’s good to know that the requirements to claim that a fiber-based packaging is compostable vary between different regions. All schemes study the characteristics of both the packaging and its components and their ability to biodegrade and disintegrate, and take into account the quality of resulting compost. There are on-going efforts in EU to create more clear and uniform guidelines on making compostability claims, and similar action is taken e.g. by the Chinese industry organizations.
Dispersion barrier coating is a sustainable option for providing oil and grease barrier properties, among others, in food packaging as it helps improve the packaging material recyclability and reduces exposure to plastics. It is also a safe alternative to replace the harmful fluorochemistries (perfluoro and polyfluoro alkyl substances, PFAS) that have already been banned in some countries. For the fiber-based packaging material manufacturers, the technology enables the production of higher value products with fewer production steps, e.g. by removing the need for a separate extrusion coating phase. Additional benefits for the paper and board producers include time, material, and production efficiency.
The first generation of FennoGuard GO already has a share of renewable bio-based raw materials to replace fossil-based chemistries, which helps further lower the environmental footprint of the food packaging material. We are committed to developing sustainable chemistry solutions and taking steps forward according to our biobased strategy to further reduce exposure to fossil-based raw materials.
Yes, FennoGuard GO provides proven functional barrier against mineral oil residual migration (MOSH and MOAH). The transfer of harmful mineral oil hydrocarbons from the food contact material to the food is a safety concern especially when recycled fibers are used in production. The latest regulatory update on the topic comes from Germany: a draft for the country’s new Mineral Oil Ordinance by the Federal Ministry for Food and Agriculture (BMEL) proposes that the use of a functional barrier is mandatory in all food contact materials that are manufactured using recycled fibers.
FennoGuard GO is compliant with key food contact regulations: EU Framework Regulation and the German BfR requirements, which provide the basis for compliance in Europe, FDA §176.170 for North American market, and the Chinese GB standard.
FennoGuard GO has proven runnability on paper and board machines and on converting lines. Convertibility is one of the key features in barrier coating for food packaging. Soft polymers offer flexible coating that gives the needed creasing and folding properties for the packaging, but typically the softer the polymer, the higher the blocking tendency. Our innovative technology overcomes the challenge and FennoGuard GO provides flexible barrier layer while also maintaining low blocking tendency.
The open formula allows us to help our customers to optimize the barrier performance for the specific packaging end use and tailor the product to meet the needs of their individual paper machines or coating lines. Kemira has excellent capabilities for simulating all the steps from coating color formulation to coating and converting in the laboratory before moving to pilot and mill trials. Barrier performance can also be tested in Kemira laboratory.
There is a broad variety of different coating methods in the industry and as each method has its pros and cons, there isn’t just one recommended method for applying dispersion barriers. There are many variables to consider when choosing the coating method, but the best performance can only be reached when a uniform, pinhole-free film is formed on the substrate. Close attention should also be paid to the coating structure, e.g. to the ability to apply thin coating layers. Functional surface barrier can also be applied at the converter utilizing printing units, such as flexography.
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