One of the biggest obstacles to replacing plastic packaging with paper has been the barrier problem. Food packaging needs to resist grease, moisture, and in some cases oxygen — properties that paper alone cannot provide. Historically, this was solved by laminating paper with polyethylene (PE) film or applying per- and polyfluoroalkyl substances (PFAS) coatings. Both approaches compromise recyclability: PE-laminated paper is difficult to recycle in standard paper mills, and PFAS coatings raise serious environmental and health concerns.
A new generation of water-based, PFAS-free barrier coatings is solving this problem, enabling paper packaging to achieve the barrier performance needed for food contact while remaining fully recyclable in standard paper recycling streams.
How they work
Water-based barrier coatings use dispersions of natural or synthetic polymers applied to paper or board substrates using conventional coating equipment (blade coating, curtain coating, or flexographic application). When dried, these coatings form a thin, continuous barrier layer that resists grease, oil, moisture, or water vapour depending on the formulation.
The key innovation is achieving barrier performance comparable to PE lamination or PFAS coatings while maintaining compatibility with paper recycling processes. During repulping (the first stage of paper recycling), the coating must either dissolve or separate cleanly from the fibre, allowing the cellulose to be recovered without contamination.
Key providers
- Michelman (US/global): Produces DigiPrime and Ecoshield water-based barrier coatings for paper and board. Grease, moisture, and water vapour barrier options. Recyclable in standard paper streams.
- Sappi (global): Produces Sappi Guard barrier papers with built-in grease and moisture resistance. Certified recyclable. Used for food wraps, trays, and sachets.
- Kotkamills (Finland): ISLA barrier board range for food service applications, replacing PE-coated board. Commercially compostable and recyclable.
- DS Smith (UK): Major corrugated packaging producer investing in barrier technology for fibre-based packaging. Operates recyclability testing laboratory in partnership with OPRL. Listed in the FuturePack directory.
PFAS-free: why it matters
PFAS — sometimes called “forever chemicals” — have been widely used as grease-resistant coatings on food packaging including takeaway containers, paper bags, and microwave popcorn bags. However, PFAS persist in the environment for decades, accumulate in living organisms, and are linked to health concerns. The EU is progressing a broad PFAS restriction proposal, and several US states have already banned PFAS in food packaging. The shift to PFAS-free water-based coatings is therefore driven by both regulatory pressure and brand reputation risk.
RAM implications
Paper packaging with water-based barrier coatings that has been certified as recyclable in standard paper streams is well-positioned for a Green RAM rating. The coating does not prevent the packaging from being collected, sorted, or reprocessed. This contrasts with PE-laminated paper, which typically fails at the reprocessing stage and receives an Amber or Red rating. For businesses looking to switch from plastic-laminated paper to a recyclable alternative, water-based coated paper is one of the most straightforward material substitutions available.