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Spray-applied biodegradable PEF/chitosan barrier for fiber bottles. Standard-nozzle compatible; low OTR/WVTR; repulpable (>85% fiber yield goal); scalable to 350 mL–1 L
About
Meet BioSpray Barrier, a biodegradable, spray-applied coating that turns fiber bottles into truly beverage-ready packaging without the crutch of thick plastic liners. Consumers and brands want to ditch fossil plastics, but today’s fiber formats still struggle with oxygen and moisture ingress, wall softening, and loss of recyclability when plastic liners are used. BioSpray Barrier tackles this head-on: our PEF-led, biopolymer-reinforced formulation is engineered for standard HVLP/air-assist nozzles to lay down thin, uniform multi-layer films on 350 mL–1 L bottles, targeting ultra-low transmission rates (OTR ≤ 2.0 cc·m⁻²·day⁻¹; WVTR ≤ 0.31 g·m⁻²·day⁻¹ at 23 °C/50% RH) so carbonation, flavor, aroma, and vitamins stay protected. Crucially, it’s designed for the paper stream, development aligns with the FBA/AF&PA repulpability standard, aiming for >85% fiber yield and minimal stickies/pick-out, so bottles can be recycled like paper, not diverted to landfill. The result is a liner-free, lightweight barrier that preserves bottle stiffness and shelf appearance, minimizes water loss and panel softening, and maintains brand printability on the exterior. Operationally, it retrofits to existing spray assets, supports fast takt times with a multi-thin-layer process window, and scales from pilot to pre-production. For regulatory and quality teams, a pragmatic migration/NIAS screen de-risks food-contact approval while durability and abrasion checks ensure real-world robustness. In short, BioSpray Barrier resolves the beverage sector’s barrier-versus-sustainability trade-off, enabling circular, high-performance fiber packaging, without compromising consumer experience or MRF compatibility.
Key Benefits
BioSpray Barrier delivers beverage-grade performance without sacrificing circularity. Built on biodegradable, bio-based resins (PEF-led blends with biopolymer reinforcement), it is engineered to be spray-applied through standard HVLP/air-assist nozzles, forming thin, uniform multi-layer films on 350 mL–1 L fiber bottles with rapid tack-dry and low add-on weight. The system targets ultra-low gas and moisture transmission—OTR ≤ 2.0 cc·m⁻²·day⁻¹ and WVTR ≤ 0.31 g·m⁻²·day⁻¹ at 23 °C/50% RH—to protect carbonation, flavor, aroma, and vitamin actives while minimizing panel softening and visible moisture staining. Because the coating is designed for repulpability, our development plan aligns with the FBA/AF&PA Voluntary Standard, aiming for >85% fiber yield and low stickies/pick-out so bottles can flow through existing paper recycling streams instead of requiring plastic separators or specialty facilities. For operations teams, BioSpray Barrier retrofits onto familiar spray lines, supports fast takt times with a multi-thin-layer process window, and maintains printability and brand aesthetics on the outer surface. For quality and regulatory stakeholders, the program includes verification at PepsiCo’s conditions (23 °C/50% RH), durability and abrasion checks on full bottles, and a pragmatic food-contact screen (overall/specific migration and NIAS) to de-risk commercialization. For sustainability leads, it quantifiably reduces fossil plastic content, supports credible ESG metrics, and is compatible with screening LCA to document cradle-to-gate impacts. Net result: a scalable, liner-free barrier that keeps beverages protected, preserves fiber recyclability, lowers material and equipment changeover costs, and strengthens on-pack sustainability claims—moving fiber bottles from “promising concept” to an industry-ready reality.
Applications
Primary: global beverage brands and bottlers moving to fiber bottles (350 mL–1 L) for still and lightly carbonated drinks: water, flavored water, juices/nectars, isotonic/sports, functional beverages, RTD tea/coffee, low-carbonation sodas.
Secondary: fiber-packaging converters and bottle manufacturers (paper mills, molded-fiber innovators) seeking an internal spray barrier; private-label retailers and contract packers piloting plastic-reduction SKUs; sustainability-driven CPGs needing recyclable, liner-free barriers for premium limited runs.
Key buyers & influencers: packaging R&D and innovation teams, sustainability/ESG leads, operations/engineering (coating lines), quality/regulatory, and procurement at multinational CPGs and large regional brands in North America, EU/UK, and APAC.