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 two- hundred-fold improvement in oxygen barrier performance over polyethylene coatings, a seven-fold improvement in moisture barrier performance, 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 can reduce plastic content up to 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 200x improvement in oxygen barrier performance over polyethylene coatings, a 7x improvement in moisture barrier, while being essentially oil-proof.
We know of no other extrusion-coated monolayer solution on the market that can achieve these barrier performance numbers.
Superior Heat Seal Performance
The mineral content in Hyperbarrier absorbs and dispels 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.
Pliable
Unlike dispersion coatings, Hyperbarrier® maintains its barrier performance when bent or folded.
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. The excellent heat seal performance allows for minimum coatweights, reducing plastic content while maintaining sealing integrity. The combined reductions in plastic provide outstanding results for brands looking to reach their plastic reduction targets and meet recyclability standards.
Recyclability
Hyperbarrier can be run at low coatweights, and contains far less plastic content than the multi-layer films that are used in paper packaging today for high-barrier performance. By being a single monolayer, coatweights are run at minimum numbers optimizing the opportunity to meet EPR regulatory standards for recyclability.
ECONOMICS
Cost Savings in Materials
HyperBarrier provides cost savings in two 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® 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.
HyperBarrier Ingredients
Polymer Resin
Nanoclay
Refined CaCO3
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.