Huber Print Solutions wipes out plastic film dependency with water barrier coating

25 Feb 2021 --- Huber Group Print Solutions is debuting a barrier coating for protection against water in food and non-food packaging surface printing.

The HYDRO-X GA Water Barrier Coating eradicates the need for polyethylene (PE) film lamination barriers using a revised water-based coating binding agents formulation.

Huber highlights paper packaging with a barrier coating is easily recycled in well-established paper recycling streams.

Changing from conventional packaging to pure paper packaging with a barrier coating is a more cost-effective and eco-friendly option, the company says.

“In coronavirus times, the biggest challenge was getting access to industrially test this solution,” Dr. Christian Schirrmacher, global project manager water-based inks, tells PackagingInsights.

“We are constantly working to develop our portfolio further. In particular, we focus on the benefits for our customers and the sustainability aspect.”

“With the HYDRO-X GA Water Barrier Coating, as a team, we have achieved another milestone.”

The HYDRO-X GA Water Barrier Coating is now available worldwide.

Economic and environmental savings
Only one inking unit is needed to apply the coating and make the shift from laminate structures to mono-material paper, bringing the following advantages: 

• Significantly improved recyclability as a well-established recycling system for pure paper packaging already exists. 
• The range of pure paper packaging applications is increased to include sectors previously reliant on PE/paper packaging. 
• Lower material costs due to savings on plastic films, now replaced by the coating. 
• Reduced processing times as PE lamination or extrusion coating is no longer required, resulting in one less step in the process.
• In a full-cost analysis, the finished product results in lower costs for a sufficient technical barrier effect.

Moisture-sensitive food protection
HYDRO-X GA provides a water-repellent surface, increasing product shelf life. The barrier coating is especially useful for moisture-sensitive foodstuffs, such as sugar, flour and dry animal food.

The solution is also suitable for non-food sectors like cement packaging and secondary packaging for copy paper, including both coated and uncoated paper.“If you have a coated and an uncoated surface side by side, you can spot the difference in gloss,” Dr. Schirrmacher tells PackagingInsights.

Real-world testing
Following successful laboratory tests, Huber began testing the coating in a real-world environment with a customer in spring 2020, involving print testing on different machines.

“The results were so impressive we immediately received an order from our customer. They were particularly impressed by the elimination of a step in the production process,” recalls Schirrmacher.

The printing ink manufacturer is expanding its water-based portfolio with HYDRO-X GA Water Barrier Coating. Dr. Lutz Frischmann, global product director flexible packaging, recognizes a clear trend toward mono-materials and therefore barrier coatings.

“At present we are working intensively to develop and manufacture additional protective coatings, such as an oxygen barrier coating. Due to the sustainability aspect, we see big potential in these product groups.”

“The oxygen barrier is in extended industrial trials [and showing] remarkably good results,” adds Schirrmacher.

Huber expects to launch more innovative coatings throughout the year.

In other water resistance innovation, DSM is releasing a portfolio of repulpable barrier coating resins, helping food manufacturers reduce the use of low-density polyethylene (LDPE).

By Joshua Poole