Using paperboard as packaging material is more sustainable
than
using plastic. To be a viable replacement, however, the barrier properties
of paperboard need to be improved. Applying a waterborne barrier coating
for both oil and water is an attractive method to improve the barrier
performance of paperboard food packaging. However, not much is known
about the oil and water barrier properties and penetration pathways
of such coatings. Here, an alkali-soluble resin (ASR)-stabilized waterborne
emulsion polymer was prepared and applied on untreated paperboard.
Its performance as oil and water barrier coating was investigated,
and the penetration pathways for both oil and water through the coating
are discussed. The presence of surface defects in the coating applied
on the paperboard strongly affects both the oil and water barrier
properties, but the coating’s morphology and chemical nature
only play a major role in the water barrier performance. The optimal
barrier performance for oil and water was achieved when adding 5 wt
% isopropanol (IPA) to the dispersion and applying two coating layers
on paperboard. The IPA improves film formation and reduces the number
of surface defects, which is explained by a more favorable spreading
coefficient of the coating over the paperboard substrate. These insights
will help to improve the oil and water barrier properties of polymer-coated
paperboard for more sustainable packaging applications.