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Designing nanotechnology coatings for replacement of fibrous white top liner

The trend toward high impact packaging at optimal cost-performance is leading to a re-evaluation of the use of white top liner in quality board applications. To replace the traditional fibrous liner structure with functional pigmented coating sets significant challenges, such as optical properties of coverage and surface opacity, but primarily in respect to the demand for high absorptive capacity when applying wet-on-wet flexographic printing. To realise the demands of high volume ink vehicle applications, a specialised coating structure based on 100 % very fine calcium carbonate, containing a large numerical proportion of ultrafine particles ≤ 100 nm (nanoparticles), is illustrated. Dependence upon formulation conditions to provide high capillarity and permeability, such that the underlying base fibre structure can act to accommodate high liquid volume transferred from the coating surface, is highlighted. The application of mercury intrusion porosimetry is used to parameterise the coating pore structure, and liquid permeability under pressure provides the liquid permeation descriptor to mimic the action of the printing nip.