DNP Develops High Barrier Paper Mono-material Sheet for Packaging, as well as other Industrial Applications

Tokyo, September 15th, Dai Nippon Printing Co., Ltd. (DNP) has developed an easy to recycle paper mono-material eco-friendly packaging sheet with high barrier properties against oxygen and water vapor. We will propose the new product as packaging materials to manufacturers of food, cosmetics, medical products and so on, and as industrial materials offered to a wider range of applications in both the domestic and overseas markets. The new product will be introduced at TOKYO PACK 2022 to be held at Tokyo Big Sight from October 12 to 14, 2022^*1. (Hall: EAST-6 , Booth: 3-49）

Packaging utilizing high barrier paper mono-material sheet 

Developmental Background

We have recently witnessed an acceleration in decarbonization efforts and ESG investment in numerous countries and regions, targeting the resolution of environmental challenges, such as climate change, global warming, and marine pollution caused by plastics. With regard to plastic products, companies and consumers around the world are working to reduce, reuse, and recycle plastic products. Packaging suppliers are developing and providing products based on plant-derived and biodegradable materials, and are focused on reducing their environmental impact. 

In response to these challenges, DNP is putting efforts into expanding our line-up of Eco-Friendly Packaging^*2, and as part of these efforts, we market highly recyclable mono-material packaging. By basing the newly developed mono-material sheet with high barrier properties on a plant-derived renewable resource - paper - instead of conventional petroleum-derived plastic film, the new product will reduce CO₂ emissions and contribute to the realization of a recycling-oriented society. 

DNP has been leveraging its proprietary converting technology^*3 to integrate barrier properties in paper, which was previously difficult to achieve and which as a result will work to facilitate the long-term storage and preservation of freshness in foods, leading to reduced food loss.

Features

Achieving high barrier properties in paper

Paper has a porous structure with fine gaps between the fibers. Consequently, it has been difficult to provide barrier against oxygen and water vapor, making it difficult to protect contents for extended periods of time when used as a packaging material. In response DNP leveraged its proprietary converting technology to develop barrier properties in paper materials at the level of oxygen permeability (OTR) of 0.5 cc/m²/day/atm^*4 or lower and water vapor transmission rate (WVTR) of 0.5 g/m²/day^*5 or lower, which had long been considered quite challenging to realize only with paper materials

In addition, we have also improved resistance to bending and minimized the impairment of barrier properties following bending. Special paper is not necessary and general craft paper can be used. 

Switching to a mono-material with a transparent barrier coating layer, it has been possible to enhance recyclability and improve conductivity

No metal materials, such as aluminium, are used in the high barrier coating layer, which is composed of paper mono-material that enhances recyclability. This high barrier paper consists of a thin layer of transparent material that has no conductivity and does not affect the transmission of radio waves, and so, it can be used with RFID applications. Furthermore, the barrier layer does not use polyvinylidene chloride (PVDC), and by weight 80% or more of the entire product uses paper.

RFID usage image

Its heat-sealability will be useful for packaging applications

The new product also maintains a heat-seal layer that can be sealed by heat welding, in addition to being a highly recyclable material due to the fact that by weight 80% or more of the entire product is paper.

Going forward

Using the current development stage as a jumping off point, we aim to commercialize the mono-material sheet for packaging materials used with food, cosmetics, and medical products, and as industrial materials offered to a wider range of applications. DNP will continue to leverage its proprietary converting technology to expand our line-up of enhanced eco-friendly products and services with enhanced barrier properties, and expand into domestic and overseas markets where demand is growing.

*1: TOKYO PACK 2022; 

- Schedule:  October 12 to 14, 2022
- Location:  Tokyo Big Sight 
                      3 Chome-11-1 Ariake, Koto City, Tokyo
- DNP booth:  Hall: EAST-6 , Booth: 3-49
- Exhibition URL:  https://www.tokyo-pack.jp/en/    

*2: For further information about eco-friendly packaging, please visit https://www.dnp.co.jp/eng/biz/solution/products/materials_package.html

*3: Converting technology is a processing technology that transforms and combines materials. DNP has strengths in processing materials such as paper and film into various formats, including film forming, coating, lamination, vapor deposition, casting, transfer dyeing, cutting, polishing, bag making, molding, and bookbinding.

*4: OTR: The amount of oxygen that passes through a 1 m² film in a 24 hour period at 1 atmosphere (atm).

*5: WVTR: The amount of water vapor that passes through a 1 m² film in a 24 hour period.

*Product prices, specification and service contents mentioned in this news release are current as of the date of publication. They may be changed at any time without notice.