The benefits of water-based coatings over PE-based

Abhay Avadhani (AA): What is the size of the coatings market for paper and packaging substrates in India?
Ashwini Sonar (AS): The market for water-based coated paper packaging in India is estimated at USD 190-mn according to HB Fuller’s custom market research.

AA: What is the update on production of coatings on the HB Fuller front?
AS: HB Fuller Earthic water-based barrier coatings are produced across the globe, including India, China, Malaysia, Europe, and the United States.

AA: What kind of certifications do you have for your product?
AS: Our products are fluorine-free, non-carcinogenic, and comply with the US Food and Drug Administration (FDA) 176.170, the German Federal Institute for Risk Assessment (BFR) XXXVI, the National Standard of the People's Republic of China (GB) 9685-2016, and the Brazilian Health Regulatory Agency (ANVISA) direct food contact compliance for maximum food safety.

AA: What about HB Fuller's Earthic water-based barrier coatings?
AS: The Earthic water-based barrier coatings has achieved Fibre Box Association Part I repulpability voluntary test method certification to support recyclable packaging.

AA: Two products in your portfolio in this segment which are very popular in India...
AS: HB Fuller Earthic 9441 and 9443.

AA: What is the chemistry of the product?
AS: The product is acrylic-based.

AA: Is the coating compatible with all printing methods?
AS: The coatings are adequate for most applications in the market which are for water-based products, like flexo printing, offset, gravure and rod coating.

AA: What is the minimum gram of coat weight to achieve the desired results?
AS: The level of coat weight depends on the customer requirements. To get an efficient barrier to water and grease, the recommended coat weight is around 10-gsm.

AA: What is the cost comparison with the normal lamination with chemical coating?
AS: The costs vary, however, we prefer to focus on the added value of enabling recyclable packaging that HB Fuller Earthic water-based coatings provide versus traditional polyethylene coatings.

AA: In view of the cost comparison, are there any superior benefits?
AS: Packages coated with PE may contaminate fibres during the repulping process, prohibiting fibre from being recycled. Whereas packages coated with our water-based barrier coatings improve fibre yield as compared to PE coatings during the repulping process. This results in the potential for higher volume of high-quality fibres to be added to the recycling stream.

AA: How do your coatings perform on the carbon footprint and recyclability scorecard?
AS: Our water-based barrier coatings provide improved packaging recyclability over polyethylene coatings.

To get an efficient barrier to water and grease, the recommended coat weight is around 10-gsm

AA: One feedback we have received from converters is: controlling the viscosity of coatings and ensuring consistency is onerous. Your view?
AS: A lack of consistent coat weight during application could result in competitor water-based barrier coatings pin holing and causing leakage. This is a challenge for the converting industry. HB Fuller Earthic water-based barrier coatings have consistent uniform coat weight to reduce overall material usage. And because we are vertically integrated and create our own polymers, we can greatly control the consistency of the finished product.

AA: Is there a knowledge gap, or technology gap in the applicator ecosystem that can be addressed?
AS: Water-based barrier coatings is an emerging market that is also evolving very quickly. This means that often HB Fuller is educating customers on appropriate application methods, coat weights, paper selection, industry moisture and grease requirements, and consulting customers on how to leverage water-based barrier coatings to enable a new sustainable packaging design.

AA: A share of polymers in sustainable food packaging applications is expected to fall by half over the next two decades. What transition are we seeing?
AS: HB Fuller’s innovation pipeline involves utilising HB Fuller Earthic water-based barrier coatings to create sustainable paper-based food service packaging. In some cases, our coatings enable brand owners to transition from plastic food packaging to fibre-based food packaging.