.png)
Barrier coatings for paper-based packaging
What if paper packaging offered full protection?
The shift from plastic to paper-based flexible packaging is reshaping the global packaging industry. Barrier coatings are the critical enabler, making it possible to use paper as packaging material while maintaining the performance that products and consumers’ demand. At Stahl, we are working with customers and partners to drive this transition: protecting what's precious, without compromise.
Benefits
Superior protection from oil and grease, water and water vapour (MVTR), and oxygen transmission (OTR)
Excellent rub, scuff and blocking resistance
Suitable for both direct and indirect food contact applications
Enables reduced material use and transport emissions
FDA-approved, ISEGA-approved, compliant with Swiss Ordinance, German Ink Ordinance
Bio-based solutions available
Unlocking the transition to responsible packaging
With the clear impacts of plastic in the environment, the world needs scalable, high-performance alternatives, particularly for small-format flexibles like sachets, wraps and pouches. These remain among the most challenging packaging types to recover and recycle, and a major source of global plastic leakage into the environment.
Paper based flexibles offer a credible future pathway, but only when they are responsibly designed and allow for easy recycling and repulping at end of life. Barrier coatings are helping to drive this transition. They determine whether paper based packaging can protect products, support circularity and avoid persistent pollution — without impacting performance or the consumer experience.
Paper-based flexibles with barrier coating properties also support compliance with policies such as the EU’s Single-Use Plastics (SUP) Directive and Packaging and Packaging Waste Regulation (PPWR), and Extended Producer Responsibility (EPR) frameworks in North America and Asia.
Introducing Stahl’s barrier coatings technology
Stahl’s barrier coatings solutions are engineered to replace plastic materials in flexible packaging across a wide range of demanding applications, from dry goods and hygiene products to direct food contact packaging traditionally served by film and foil.
All our formulations support the recyclability and repulpability of the finished packaging structure, and comply with regional and global food contact regulations. Our technology addresses:
Water vapour and moisture resistance
- Critical for dry goods, hygiene products and food packaging where humidity control determines shelf life.
Water vapour and moisture resistance
Oxygen transmission barriers
Rub and scuff resistance
Repura™: Barrier coatings for paper-based packaging
Protect food and goods against water vapour, oxygen, fat, oil and grease with high-performance barrier coatings for paper packaging.
Superior protection from oil and grease, water and water vapour (MVTR), and oxygen transmission (OTR)
Excellent rub, scuff and blocking resistance
Suitable for both direct and indirect food contact applications
Enables reduced material use and transport emissions
FDA-approved
From concept to scale-up: how we work with customers
Every substrate behaves differently. Coating weight, application method, drying parameters, the interaction between coating and downstream converting processes — these variables have to be worked through in application trials. A formulation that performs in a lab can behave differently on a commercial coater at speed.
Stahl’s technicians draw on decades of coating innovation to help customers make sense of this complexity. We partner with converters, brand owners, papermakers and packaging designers to tailor barrier solutions to specific substrates, machinery, regional regulations, and performance requirements.
Local technical support offering
Our local technical teams provide expert, hands-on support from concept through scale‑up:
Coating selection
Application trials
Optimisation of machine settings
Regulatory and food-contact considerations
Recyclability testing
Industrialisation and quality scaling
Frequently Asked Questions
Please get in touch and send us your question if it is not listed below.
What specific performance benefits can customers expect from Stahl's barrier coatings?
- Our barrier coatings protect food and goods, extend shelf life and support efficient production. This includes superior protection against oil and grease, water and water vapour (MVTR), and oxygen transmission (OTR). Our technology also enables material reduction through excellent rub, scuff and blocking resistance, allowing the use of thinner papers and reducing transport emissions.
What packaging applications are supported by Stahl’s barrier coatings technology?
What kind of protection do Stahl’s barrier coatings provide for direct food applications?
Can Stahl provide technical support during the development process?
Do Stahl’s barrier coatings range comply with relevant regulations in my region?
Key takeways:
Barrier coatings are a critical enabler of the plastics-to-paper transition in packaging.
Responsible packaging design requires optimising across six criteria simultaneously; Stahl’s barrier coating technology builds to support all of them.
Performance and circularity are not a trade-off. Stahl's formulations are engineered to deliver both.
Expert technical support from concept to scale-up is built into how Stahl works, not offered as an add-on
Stahl’s technical teams are engineering the next frontier: bio-based, high-barrier, dual end-of-life pathways.
.png)
About the author:
André Garber - Head of Business Development Packaging Coatings (EMEA), leads business development for Packaging Coatings across EMEA, focusing on driving sustainable growth through customer‑centric solutions and strategic partnerships.
Angela Smits - Sustainability Manager Packaging Coatings, focuses on advancing sustainability initiatives and integrating ESG principles within packaging coating solutions.
Contact us
