Alternative fibers and micro-fibrillated cellulose coated packaging papers, and films and substrates

Abstract

Sustainable paper-based packaging materials, e.g., packaging materials comprising agro-based microfibrillated cellulose (A-MFC), are described. The packaging materials include coatings and films prepared from A-MFC derived from hemp hurds, cocoa pod husks, and other agro-residues or byproducts and having a high level of primary and/or secondary fines. Methods of preparing the A-MFC can involve a reduced amount of energy compared to wood-derived materials and the packaging materials can have enhanced barrier and mechanical properties, such as enhanced oil and grease resistance.

1 . A packaging material comprising a film or a coating layer comprising agro-based microfibrillated cellulose (A-MFC), wherein said A-MFC comprises a microfibrillated cellulose (MFC) prepared from a pulp from a non-wood lignocellulosic feedstock, wherein the film or coating layer has a weight gain of less than about 5 percent (%) and/or less than about 2.5 grams per square meter (g/m 2 ), when contacted with hot oil for 20 minutes, wherein said hot oil has a temperature of about 65 degrees Celsius (° C.). 
     
     
         2 . The packaging material of  claim 1 , wherein the non-wood lignocellulosic feedstock comprises one or more agricultural residue and/or industrial by-product. 
     
     
         3 . The packaging material of  claim 2 , wherein the non-wood lignocellulosic feedstock is selected from the group consisting of hemp hurds, a mixture of hemp hurds and hemp bast, bagasse, cocoa pod husks, and combinations thereof. 
     
     
         4 . The packaging material of  claim 1 , wherein the A-MFC comprises modified A-MFC, wherein the modified A-MFC comprises MFC derived from a chemically modified pulp. 
     
     
         5 . The packaging material of  claim 4 , wherein the modified A-MFC comprises carboxymethylated A-MFC; oxidized A-MFC; carboxymethylated and oxidized MFC; or a combination thereof. 
     
     
         6 . The packaging material of  claim 5 , wherein the oxidized A-MFC comprises dialdehyde cellulose. 
     
     
         7 . The packaging material of  claim 1 , wherein the film or coating layer comprises about 5 weight percent (wt %) to about 90 wt % A-MFC. 
     
     
         8 . The packaging material of  claim 1 , wherein the film or coating layer further comprises one or more of chitosan, cationic starch, glycerol, triethyl citrate, a polyhydroxyalkanoate (PHA), and alkyl ketene dimer (AKD). 
     
     
         9 . The packaging material of  claim 1 , wherein the A-MFC has a total fines level of about 50% to about 95%. 
     
     
         10 . The packaging material of  claim 1 , wherein the A-MFC has an average fiber length of about 0.1 mm to about 0.45 mm. 
     
     
         11 . The packaging material of  claim 1 , wherein the film or coating layer has a thickness of about 1 micrometer to about 200 micrometers. 
     
     
         12 . The packaging material of  claim 1 , wherein the film or coating layer has a bulk of about 0.5 cubic centimeters per gram (cm 3 /g) to about 2.0 cm 3 /g. 
     
     
         13 . The packaging material of  claim 1 , wherein the film or coating layer has a weight gain of less than about 2% and/or less than about 1.19 g/m 2 , when contacted with hot oil for 20 minutes, wherein said hot oil has a temperature of about 65 degrees ° C. 
     
     
         14 . The packaging material of  claim 1 , wherein the film or coating layer has a weight gain of less than about 3% and/or less than about 1.8 g/m 2  when contacted with room temperature oil for 15 hours. 
     
     
         15 . The packaging material of  claim 1 , wherein the film or coating layer has a water vapor transmission rate (WVTR) of less than 50 grams per square meter millimeter per day (g/m 2 ·mm/day). 
     
     
         16 . The packaging material of  claim 1 , wherein the film or coating layer has a density of about 0.3 grams per cubic centimeter (g/cm 3 ) to about 2.1 g/cm 3 . 
     
     
         17 . The packaging material of  claim 1 , wherein the film or coating layer has a tensile index of about 30 Newton meter per gram (Nm/g) or more. 
     
     
         18 . The packaging material of  claim 1 , wherein the film or coating layer has a stretch of about 1.5% or higher. 
     
     
         19 . The packaging material of  claim 1 , wherein the packaging material is a food or beverage packaging material. 
     
     
         20 . The packaging material of  claim 1 , wherein the packaging material further comprises a substrate, wherein said substrate is coated on at least one surface by the film or coating layer comprising A-MFC, wherein the substrate is a flexible substrate, and wherein the substrate comprises paper or another biodegradable and/or sustainable material, wherein the paper further comprises papermaking fibers derived from a waste biomass. 
     
     
         21 .- 35 . (canceled)