Paper-based food packaging materials are widely used, renewable, and biodegradable. Because of its porous structure, paper has poor or no barrier performance against grease, water vapor, water, and volatile organic compounds. Moreover, recycled paperboard can be a source of organic residuals that are able to migrate into packed food. Two different types of paperboard produced from primary and secondary cellulosic fibers were coated using renewable materials, such as alginate and chitosan, and comprehensive barrier measurements showed multifunctional barrier properties of these two biomaterials. Both paper substrates were successfully coated using a draw-down coater, and the measured air permeability of the coated samples was 0 mL·min⁻¹. Grease resistance was improved, while it was possible to reduce water vapor transmission, the migration of mineral oil saturated hydrocarbons and mineral oil aromatic hydrocarbons (MOSH/MOAH), and the permeation of volatile compounds for both paper substrates when compared with uncoated substrates. Wettability and water absorptiveness of chitosan- and alginate-coated papers were found to be substrate-dependent properties, and could be significantly affected by bio-based coatings. In summary, industrially produced paperboard was upgraded by coating it with the naturally biodegradable biopolymers, alginate and chitosan, thus achieving extraordinary barrier performance for various applications within the packaging industry.

Chitosan is a versatile biopolymer with many interesting functionalities. Its effects on the barrier and mechanical properties of single- or double-coated fibre-based packaging papers in dependence on the applied drying regime were successfully tested. Our investigations revealed chitosan to be a highly robust biopolymer, since the different drying regimes did not alter its contribution to the development of strength and barrier properties of the coated packaging papers. These properties showed a stronger influence of the applied coat weights than of the different drying regimes. The effect of chitosan coatings were quantified by measuring tensile strength (TS), burst strength (BS) and tensile energy absorption (TEA). These revealed that TS, BS and TEA of the coated papers increased significantly. Moreover, the chitosan-coated papers were less permeable against water vapor and air. High grease resistance was observed for double-coated papers, irrespective of the drying regimes. The coated paper surface showed a more hydrophilic character, resulting in lower contact angles and higher water absorption properties. In this study, industrially produced chitosan has been proven to be a renewable, robust biopolymer that can be utilized as an additive to increase strength and the barrier properties of fibre-based materials.

Cellulose-based packaging materials are currently the most commonly used food packaging materials due to their light weight, stability and affordable price. However, the use of recycled paper and board adds to the risk that undesirable substances migrate into the packed goods, since contaminants are not completely removed during the recycling process and can accumulate in the final product. The only available fast and practical solution that can be used to reduce the migration of these substances is the application of functional barriers in the packaging. The applied barriers are currently mostly synthetic, which either serve only a moderate barrier function and/or have the disadvantage that it is often more complex and expensive to recycle the resulting packaging material. The aim of this project is to evaluate different bio-based or biodegradable polymers with regards to their barrier properties. Due to the fact that the transport phenomena are mainly driven by (gas phase) migration, methods based on gas chromatography (GC), including GC coupled with mass spectrometry (GC-MS) and flame ionization detection (GC-FID), GC-FID coupled online with high pressure liquid chromatography (HPLC-GC-FID), and comprehensive GCxGC-MS were used to qualify and quantify the migrated substances. This use of a wide range of different methods and instruments yielded excellent results, allowing us to comprehensively characterize the biopolymers and their barrier function.

The current demand to cut back on the use of plastic materials has brought a major boost to the search for bio-based alternatives. Not only are plastic bags and primary food packaging under scrutiny here, but also those materials used as functional barriers to reduce, for example, the migration of mineral oil hydrocarbons (MOH) from recycled paper and board packaging. Most of the barriers now in use are synthetic, often have only moderate barrier functionalities and in addition reduce the environmentally-friendly character of cellulose-based materials. Against this background, bio-based polymers have been evaluated in terms of their functional barrier properties. Chitosan was found to be among the best performers in these materials. In this study, the behavior of a lab-made chitosan acetate film was compared with conventionally produced polymer films. The two-sided migration experiment described recently was used to determine the barrier properties of the tested materials. This not only allowed to test the intrinsic migration of the films and the permeation through them, but also to simulate real packaging situations by using a recycled paper as donor for MOH. The migrated fractions were determined using gas-chromatography-based techniques. While the conventionally produced polymer films showed only moderate barrier function, excellent results were seen for the biopolymer. It reduced the migration from the recycled paper to not detectable, singling it out as a good alternative to conventional materials.