A Q&A around barrier technology with a packaging expert
Barrier technology plays a crucial role in modern packaging, protecting products from oxygen, moisture, light, and contaminants that can compromise quality and shelf life. From food preservation to pharmaceutical stability, advanced barrier materials are transforming how we package and protect goods.
DS Smith’s Susana Aucejo gives MT readers an overview of the current options.
What are your latest barrier coating solutions and what are their key benefits?
DS Smith barrier solutions protect packaging and/or product from water, grease and help to minimize abrasion, particularly if we are reducing or removing entirely plastic content such as laminated layers.
We use different technologies depending on the application, ranging from coating, printing, and lamination. These methods are employed selectively, depending on the level of protection required and how targeted it needs to be. We always look to strike a balance between barrier performance and cost-effectiveness.
Increasingly customers are looking for barrier solutions for food products, so all our developments are rigorously assessed for food safety compliance. Our barrier technologies also extend to other high-value-added packaging solutions, such as those targeting oxygen and aroma barriers.
Importantly, we evaluate the recyclability of the barrier materials to ensure that solutions align with circular economy principles, and the packaging can be effectively recycled at the end of their life cycle.
Why is barrier coating innovation currently such an important focus for packaging suppliers?
There is no denying the packaging industry is facing a tremendous challenge to fulfil the sustainability agenda. Consumers also want less plastic packaging entering their homes, without compromising the functional capabilities in the products.
Legislative initiatives in Europe to tackle plastic waste and other issues such as recycling rates are starting to come into force from 2026, for example the EU Packaging and Packaging Waste Regulation (PPWR). This means we are helping more of our customers to deliver on plastic replacement by using naturally occurring materials or simply reducing the current plastic content of their packaging.
Fiber-based material can have challenges; it is porous so allows gases to pass through. Barrier technology can enhance this material and help meet current market challenges, but it is not a one size fits all. We work on bespoke solutions for our customers that ensure protection and effective delivery throughout a supply chain cycle, where there are many interactions between the environment, the packaging, and the product.
In what ways are you innovating for more effective barrier coatings, and what challenges are you working to overcome?
Due to pressure from legislation and market needs, there are increasing numbers of new developments to replace oil-based barriers with innovative options that are coming from biomass or natural polymers. Many materials that are being investigated currently will become the next generation of barrier materials.
Often, we are co-creating, working in partnership with different universities and research institutes, and with our strategic suppliers to improve barrier functionality. We are also seeking alternatives to fossil-based barriers which can be used in our existing equipment and machines.
The main challenges that we face are related to performance and cost. For example, some of the most sustainable barriers are sensitive to water but can usually provide effective protection against grease and often to gases. New materials are usually more expensive that the traditional ones, so it is not always possible to apply them in the business, but this will change in time as we continue to innovate.
Another key challenge is the scalability of these processes. Some of the new materials are still in early stages development, so big scale production is still to come.
In what ways can new barrier coatings support the industry’s drive
for greater environmental sustainability?
for greater environmental sustainability?Aside from reducing plastic layers and fossil fuel-based materials, effective barriers can help to preserve food longer, extending shelf life and reducing spoilage and food waste.
Advance coatings can achieve required barrier properties with much thinner layers than laminated plastics. This drive to lighter materials improving resource efficiency.
Barrier developments are helping the industry to comply with stricter regulations on packaging materials, so we are supporting our customers with not only understanding the changes and what they mean, but with solutions that make an impact.
Susana Aucejo
DS Smith is a leading global provider of sustainable fibre-based packaging, which is supported by recycling and papermaking operations. The company plays a central role in the value chain across sectors including e-commerce, fast moving consumer goods, food and beverage, and industrials. It has a target-led Now & Next sustainability strategy, Redefining Packaging for a Changing World and is committed to leading an industry-wide transition to a circular economy while delivering sustainable circular solutions for customers.
International Paper is the global leader in sustainable packaging solutions. With company headquarters in Memphis, Tennessee, USA, and EMEA (Europe, Middle East, and Africa) headquarters in London, UK, it employs more than 65,000 team members and serves customers around the world with operations in more than 30 countries.