Novel Starch-Based Coatings to Improve the Surface, Mechanical, and Physical Performance of Recycled Paperboards for Packaging Applications

Document Type : Original Article

Authors

1 Manipal Institute of Technology, Manipal Academy of higer Education, Manipal 576104, India

2 Department of Chemistry, Alva’s Institute of Engineering and Technology, Moodbidri-574225, Karnataka, India

Abstract

This study developed and characterized three novel biodegradable coating formulations based on rice, wheat, and corn starches, blended with sorbitol, polyethene glycol, and carboxymethyl cellulose. These coatings were applied to recycled paperboard using a bar coater to improve its mechanical and barrier properties for packaging applications. Comprehensive evaluation revealed that the wheat starch-based coating yielded the most significant enhancements. The application of this coating increased the bursting strength of uncoated recycled paperboards by 42.42 % and edgewise compression strength (ECT) by 8.6 %, while reducing the Cobb value by 22.89 % and porosity by 
10.28 %. Furthermore, it substantially improved barrier performance, reducing water vapor permeability (WVP) by 49.5 %, and enhanced optical properties, increasing brightness by 1% and reducing color difference by 4.3%. The superior color printability observed for wheat-starch-coated boards is attributed to combined improvements in surface properties and reduced porosity. Statistical validation via one-way ANOVA confirmed the significance of the results. Microscopic analysis (SEM and AFM) demonstrated improved surface evenness and smoothness for all coated samples. FTIR spectroscopy in the 960–1060 cm⁻¹ region showed a decrease in light transmittance after coating, with the wheat-based formulation showing the greatest reduction (from 55 % for uncoated paperboard to 41 %), indicating effective surface coverage and interaction. The findings confirm that these starch-based coatings, particularly the wheat starch formulation, are effective in improving the strength, barrier, and printability performance of recycled paperboards.

Keywords

Main Subjects

References

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Progress in Color, Colorants and Coatings
Volume 19, Issue 4 - Serial Number 63
October 2026
Pages 467-483

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