for Flexible Packaging
HyperBarrier is a groundbreaking innovation in the realm of sustainable packaging solutions. Engineered to address the pressing challenges of the packaging industry, EC HyperBarrier is a ternary nanocomposite coating, setting a new standard for oxygen barrier performance, sustainability, and cost-effectiveness in paper-based flexible packaging.
Unparalleled Oxygen Barrier Performance for an Extrusion Coating Monolayer Barrier
HyperBarrier delivers an unprecedented twenty-fold improvement in oxygen barrier performance compared to conventional polyethylene extrusion coatings. This remarkable advancement ensures product integrity, extending the shelf life of a wide array of products by providing superior protection against oxygen, moisture, and oils, while avoiding complex and expensive multilayer film laminations.
A Leap Forward in Sustainability for Flexible Packaging
In our continuous pursuit of environmental stewardship, HyperBarrier represents a significant stride forward. This innovative coating not only reduces plastic content by an additional 35% beyond the transition from plastic to paper packaging but also ensures compatibility with existing paper recycling streams. By facilitating the recycling of paper-based flexible packaging as uncoated paper, EC HyperBarrier enhances the quality of recovered paper bales and minimizes waste, contributing to a more sustainable future.
Cost-Effective and Industry-Friendly
HyperBarrier emerges as a cost-effective solution by eliminating the need for complex, multi-layer structures, thereby reducing material and production costs. Designed as a monolayer extrusion coating solution, it simplifies the manufacturing process without requiring capital expenditure or modifications to existing production lines. This drop-in solution seamlessly integrates into current manufacturing practices, ensuring a smooth transition for industries looking to adopt more sustainable packaging options.
The Smart Planet Technologies Advantage
At Smart Planet Technologies, we are committed to pioneering sustainable barrier coatings and packaging materials that do not compromise on performance. Our innovations, including HyperBarrier, are designed to make disposable packaging "recycle-ready," aligning with our vision of a circular economy where all paper packaging becomes a valuable resource.
A Better Barrier Technology in Every Facet
HyperBarrier is not just an improvement; it's a transformation in barrier technology for flexible packaging. With its exceptional oxygen barrier capabilities, recyclability, and reduced plastic content, in a HyperBarrier offers a comprehensive solution that addresses the industry's environmental and functional needs. This combination of advantages opens new doors for companies to explore paper-based flexible packaging, marking a paradigm shift towards more sustainable packaging solutions.
Key features:
Unmatched Oxygen, Moisture, and Oil Barrier performance in extrusion-coating paper-based packaging: HyperBarrier delivers a twenty-fold improvement in oxygen barrier performance over polyethylene coatings, while also enhancing barrier performance for moisture and oils, ensuring product integrity and extending shelf life for a wide range of applications.
Cost-Effective Choice: Hyperbarrier is a monolayer extrusion coating solution eliminates the need for complex and expensive multi-layer structures, offering a more affordable and efficient solution.
Recyclability: As with the suite of Smart Planet’s EarthCoating products, HyperBarrier creates paper-based flexible packaging materials that are compatible with existing paper recycling streams as uncoated paper, improving bale quality of recovered paper and reducing waste.
Plastic reduction: With its mineralized formulation, Hyperbarrier reduces plastic content an additional 35% beyond the plastic reduction from switching from plastic to paper packaging.
Fit for Purpose: Hyperbarrier has all of the capabilities in conventional coatings, including heat-sealability, and food contact certifications
Industry-Friendly Integration: This drop-in solution requires no capital expenditure or changes to existing manufacturing processes, ensuring smooth adoption.
Table of Barrier Films and Coatings in Paper-based Packaging for Food Contact
FEATURES & BENEFITS
PERFORMANCE
Superior Barrier for Oxygen, Moisture and Oils
The combination of mineral types in Hyperbarrier® produce a tortuous path for oxygen, moisture and oils to pass through, resulting in better barrier performance across all three measurements over any other extrusion coating formulation available. Hyperbarrier provides a 20x improvement in oxygen barrier performance over polyethylene coatings, while becoming waterproof and oil-proof.
There is no extrusion coating solution on the market that can achieve these barrier performance numbers.
Superior Heat Seal Performance
The mineral content in Hyperbarrier, absorb and dispel heat more rapidly than neat polyolefins. This results in more heat activation of the polymer, while occuring faster, providing better heat seal performance and improved fiber tear testing over neat polyolefins.
High Quality Print Surface
Unlike traditional polyethylene, Hyperbarrier® offers a high surface energy complete with a typical post-corona dyne level of 46, providing an excellent print surface for high quality graphics using digital, offset, flexo and rotogravure printing techniques.
ENVIRONMENT
Plastic Reduction
Because of the outstanding barrier performance in Hyperbarrier, many plastic packaging applications can be switched to paper-based resulting in a reduction of plastic usage. In addition, the mineral content in Hyperbarrier® offsets 40% of the plastic by weight that would otherwise be found in a conventional barrier-coated paper packaging. The combined reductions in plastic provide outstanding results for brands looking to reach their plastic reduction targets.
Recyclability
Hyperbarrier leverages the benefits of mineralization, as used in EarthCoating to provide the same capabilities to produce paper-based packaging that is compatible with paper recycling systems. Hyperbarrier is a formulation that has been classified as an inert coating for the purposes of recycling, along with clay coatings. Packaging with Hyperbarrier can be mixed in recovered paper bales along with uncoated paper packaging, providing premium bales for the paper recycling industry, without concerns for plastic contamination.
By contrast, packaging applications made with Hyperbarrier can be easily processed using conventional paper recycling equipment. Like a clay coating, Hperbarrier is denser than water because of the mineral content and falls to the bottom of the pulper with clay coating, paper clips, staples, and other items to be removed in the recycling process. That leaves the paper fibers to be collected cleanly from the pulper without barrier coating contamination. Recycling tests of packaging with EarthCoating is done successfully with bales containing 100% packaging coated with Hperbarrier, and the materials are qualfied for collection in uncoated paper grades.
Since the use of Hyperbarrier provides sufficient barrier in many applications for plastic packaging to be replaced with paper packaging, the challenges of the lack of recycling of plastic-based flexible packaging can be averted.
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ECONOMICS
Cost Savings in Materials
HyperBarrier provides cost savings in three ways
HyperBarrier is an extrusion coating layer with outstanding oxygen barrier performance, which can replace the use of multilayer EVOH film laminations, and metallized film laminations in many packaging applications. Extrusion coating is a far more cost-effective manufacturing process over extrusion lamination processes
HyperBarrier is a ternary nanocomposite, including up to 40% of microparticle mineral and nanoparticle clay ingredients, which offset expensive polymers.
Hyperbarrier® provides superior barrier performance, which often results in an opportunity to down gauge coat weights, leading to source reduction and potential cost savings over conventional paper barrier coatings.
Post-Industrial Trimmings Rebate
Paper-based packaging applications coated with Hyperbarrier® are engineered for repulping through existing paper recycling streams, providing premium high value fibers without plastic contamination nor a laborious depolymerization process found in the effort to process traditional paperboards with 100% polyolefin coatings. As a result, industrial Hyperbarrier® trimmings are sought after at a premium value by recyclers, resulting in a potential rebate for supply chain vendors.
HyperBarrier Ingredients
Refined CaCO3 and Nanoclay 100% Polymer resin
Refined CaCO3 and Nanoclay in a proprietary formulation are blended into polyolefin resin, creating Hyperbarrier, a unique monolayer extrusion coating formulation with superior Oxygen, Moisture and Oil barrier performance.
This performance combination provides many opportunities for companies to switch from plastic flexible packaging to paper-based flexible packaging, with sufficient heat seat and barrier performance, and adding recyclability in the paper recycling stream.