Designing paper and board barrier constructions for food contact applications, TAPPI Journal November 2025

Application: A better understanding of key attributes driving barrier performance in coated paperboard articles is needed. We utilized an industrial pilot coater to produce several purpose-built barrier constructions, with a focus on the impact of coating application method and latex chemistry on liquid water, moisture, and oil barrier.

Author: Alan M. Piwowar and Greg Welsch

ABSTRACT: This study examines the effect of multiple factors on barrier performance for purpose-built paper and paperboard constructions produced on an industrial pilot coater machine. Impacts from precoat latex chemistry, application method (flooded nip with bevel blade, jet with bevel blade, and pre-metered film coater, laboratory rod drawdown) and precoating calendering were studied in relation to resulting porosity, roughness, and barrier (liquid water, moisture, and oil). Results reveal a complex interaction between controllable and uncontrollable factors, offering insight for designing advanced barrier coatings on cellulosic substrates.