TAPPI grounds aqueous barrier coatings in operational reality for packaging converters

Moving beyond the sustainability pitch

Today in Atlanta, TAPPI opens its 2026 Aqueous Barrier Coating Course, marking a definitive industry shift. The conversation around water-based barriers for paperboard packaging is no longer just about sustainability targets; it is now strictly about operational execution, rheology, and machine runnability.

For years, converters and paperboard producers have chased aqueous coatings to meet stringent recyclability thresholds, often aiming for the sub-2% non-cellulosic content required in the US or the strict plastic-free certifications in Europe. However, applying these dispersions introduces complex manufacturing variables. High moisture content can disrupt tray forming, and clay-based dispersions risk flaking during carton folding. The three-day program at the Embassy Suites Atlanta Galleria addresses these exact friction points on the factory floor.

Technical rigor on the factory floor

Led by industry veterans including Prakash Malla and John Roper, the curriculum dissects the entire coating architecture. The sessions move from base paperboard substrates and pigment selection to the specific behaviors of synthetic and biobased polymers. Crucially, the technical focus zeroes in on coating consolidation, drying dynamics, and the mitigation of fold cracking—defects that can compromise the barrier integrity of a food-grade carton before it ever reaches the retail shelf.

Moving beyond classroom theory, the program integrates physical validation. Attendees will analyze live barrier testing demonstrations at the Applied Paper Technology laboratory. Furthermore, the operational deep-dive extends to Georgia Tech's Renewable Bioproducts Institute (RBI), where researchers like Dr. Meisha Shofner will bridge the gap between renewable feedstocks and functional food packaging through pilot-scale system evaluations.

By anchoring the curriculum in rheology, application methods, and defect troubleshooting, TAPPI is equipping packaging manufacturers with the technical rigor required to scale aqueous barriers. The industry has already accepted the environmental mandate for these materials; the current challenge is making them run flawlessly at commercial speeds.