Most of the products we consume today come encased in some form of packaging. Barrier coating is a layer applied to packaging. It protects the product from external factors like contaminants, humidity, oxidation, and sunlight. In this article, we explore what barrier coating is, its contribution to the packaging industry, and DIC India’s range of top-quality barrier coatings.

What is Barrier Coating?

Barrier coating is the thin protective layer applied to packaging materials. It can be applied both inside as well as on the outer covering of the packaging. It is like an invisible shield designed to keep external threats like moisture, oxygen, and other contaminants from getting in. This layer helps the products remain fresh, extends their shelf life, and makes sure their quality remains unaffected during the journey from the factory to the consumer.

Water-Based Barrier Coatings

Earlier, barrier films were used that were made from materials like aluminium foils or speciality films. This made recycling the packaging a very complicated, and at times, an impossible process. Given the growing concern over environmental issues, packaging too needs to meet growing expectations for recyclability; it needs to be effective as well as sustainable.

The packaging industry began the hunt for alternatives that could be recycled. The solution came in the form of water-based barrier coatings, a game-changer for sustainability. These coatings are free from harmful chemicals like chlorine, making them a much cleaner choice for the environment.

Types of Water-Based Barrier Coatings

Barrier coatings come in two main types, depending on what kind of packaging they’re used for.

● For paper packaging, the coating acts as a shield. This stops the paper from soaking up moisture and getting weak. It also helps in sealing the paper properly, so that the product inside stays safe.

● For plastic (polyolefin) packaging, the coating creates a thin layer that blocks oxygen from getting through. Since oxygen can cause food to spoil faster, this coating helps the food or product inside to stay fresh for longer.

These coatings can be applied through gravure, flexo, or offset processes. Barrier coatings are available in both water-based and solvent-based formulations.

DIC India's Range of Barrier Coatings

DIC India is a well-known name in printing inks and packaging solutions, and has developed a wide portfolio of water-based barrier coatings. With their dedicated product lines - SunSys, Sunstar, Hydbar, and Sunbar for films, DIC India offers solutions that are both durable and can be recycled. Each of the products has been engineered to support different packaging structures.

● SunSys®FS241 is heat-resistant and prevents wrinkles and whitening at the seals of polyolefin films. This ensures a stronger, more reliable seal. It is best suited to polyolefin-type mono-material packaging.

● Sunbar is a lightweight, transparent, chlorine-free, and recyclable barrier coating that integrates oxygen barrier properties into mono-material structures (can be used in films).

● SUNSTAR is a water-based overprint varnish designed for direct food contact on natural fibre paper and carton board packaging. It provides both water and oil resistance, eliminating the need for plastic in the final product.

● HYDBAR protects paper surfaces and improves paper and carton board substrates’ water and oil resistance. These coatings are used in exterior applications on packaging where the contents are not in direct contact with the coating.

● PASLIM® is a barrier solution made for flexible packaging that strengthens oxygen resistance and helps extend the shelf life of flexible packaging. It enhances oxygen barrier performance and makes it possible to replace traditional nylon or PET-based multilayer laminates with simpler mono-material structures.

Applications Across Sectors

● Food and Beverages: Barrier coatings protect against the detrimental effects of air and moisture. Food remains fresher for longer while maintaining its distinct flavour and aroma. For example, snack packets, cups for beverages, and frozen food coverings all depend on barrier coatings to preserve quality.

● Consumer Goods: Many products, especially oily or greasy ones, depend on barrier coatings to prevent stains and leaks. This keeps the packaging intact, plus it makes the product appealing on the shelf. It is because of barrier coating that detergent cartons, fast-food takeaway boxes, or cosmetics packaging stay neat and spill-free.

● Pharmaceuticals: Medicines and health products need extra protection. Barrier coatings offer resistance against external contaminants while also maintaining safety and compliance standards. Blister packs, medicine bottles, and medical sachets all require barrier coatings.

The transition to sustainable packaging is a necessity. With cleaner products and a commitment to reducing environmental impact, companies like DIC India are not just protecting products; they're also protecting the planet.

To learn more about their barrier coating offerings, visit the DIC India website today.