Recyclable ultra-high barrier paper for blister packaging using AP-SALD

Overview

Nfinite Nanotech has developed an innovative recyclable ultra-high barrier paper suitable for blister packaging applications. Utilizing AP-SALD (spatial atomic layer deposition), this technology applies ultrathin, conformal metal oxide coatings that create highly effective barriers against moisture and oxygen. The resulting packaging materials achieve a water vapor transmission rate (WVTR) of less than 0.2 g/m²/day and an oxygen transmission rate (OTR) of less than 0.5 cc/m²/day, comparable to metallized plastics. This breakthrough enables the use of paper as a sustainable alternative in the packaging industry, supporting both environmental goals and performance requirements.

Technical specifications

• AP-SALD Coating Process: Non-vacuum, roll-to-roll process for ultrathin metal oxide coatings under 100 nm.
• Barrier Performance: WVTR <0.2 g/m²/day at 38°C/90% RH and OTR <0.5 cc/m²/day at 23°C/50% RH.
• Packaging Structure: Incorporates a 4–5 gsm heat sealant and 2–4 gsm organic photovoltaic (OPV) layer, ensuring recyclability with water-based dispersions.
• Production Scale: Capable of producing A4 sheets and 12" reels, with plans to scale to 36" reels via a pilot plant.
• Material Composition: Maintains over 85% fiber content, aiming for more than 95%.
• Compatibility: Coatings are compatible with various top coating processes including water-based, lamination, and extrusion layers.

Technology readiness level

This technology is currently at Technology Readiness Level 3, with successful lab-scale demonstrations. Future plans include scaling production to 36" reels and enhancing barrier performance and flex-crack resistance for commercial deployment.