Wax replacement alternative technology for corrugated containers is becoming increasingly prevalent,but further promotion of this technology in industry requires improvement of its economic performance compared to wax.Incorporation of pigments with appropriate characteristics can increase barrier properties of coatings and improve the economics of wax-alternative coatings.This paper demonstrates through laboratory trials the possibilities for improving water resistance by using clay base coats followed by a polymer top coat in a two-stage coating process.The combination improves the polymer coating quality while increasing the compressive strength of linerboard,allowing a reduction in the required weights of polymer top coat and linerboard and thus achieving increased performance and cost effectiveness.Incorporation of platy clays and talc as blends with an acrylic polymer was also investigated,along with calendering,to develop a best-case scenario featuring process simplicity and optimal economics.
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