Multilayer Barrier Coatings with Starch/Bentonite for Paperboard—The Effects of the Number of Layers and the Drying Strategy on the Barrier Properties

This study investigates the impact of multilayer structures and drying strategies on the barrier properties of high-speed starch/bentonite-coated paperboard. The study examines the impact of drying at a high machine speed of 400 m min−1, addressing a key knowledge gap. The hypotheses were that thin multilayer coatings reduce oxygen permeability more effectively than thick single or double coatings and that gentle infrared (IR) drying would be required to achieve this effect. The experiments comprised up to six consecutive coating applications, each providing a dry coat weight between 0.5 and 1.5 g m−2. The IR dryer power ranged from 207 kW to 829 kW, and different IR frame positions were tested. The results indicated that thin multilayer coatings resulted in fewer pinholes, lower oxygen transmission rates, and improved grease resistance compared with one or two thick layers. However, the effectiveness of the multilayer-coated paperboard was influenced by the employed drying strategy. Specifically, gentle IR drying reduced pinholes, lowered oxygen transmission rates and enhanced grease resistance.