Preparation and benchmarking of novel cellulose nanopaper

Synthetic polymers and plastics which are currently used as barrier materials in packaging applications are neither renewable nor biodegradable. Nanopaper, which is obtained by breaking down cellulose fibers into nanoscale particles, have unique properties with the potential to replace synthetic packaging materials, but requires very high energy to mechanically process the fibers into nanopaper. This research investigates whether refining alone can be used to produce nanopaper with sufficient quality for packaging applications. Nanopaper was produced from Bleached Eucalyptus Kraft (BEK) refined with a PFI mill and from Northern Bleached Softwood Kraft (NBSK) refined in a pilot disc refiner. Both trials found a plateau for oxygen permeability and water vapour permeability that was reached after 1800 kWh/t and 12,000 kWh/t for refining in the pilot disc refiner and PFI mill, respectively. Refining beyond these optima produced either little or no reduction in permeability, while increasing the drainage time to form a sheet. However, elastic modulus, strain at break and sheet light transmittance did continue to increase. The plateau oxygen permeability of ~ 1.24 (cc µm)/(m(2) day kPa) is 1–3 orders of magnitude lower than the oxygen permeability for PET and LDPE, respectively, while the plateau water vapour permeability ~ 3 × 10(–11) g/m.s. Pa was 1–2 orders of magnitude higher than for PET and LDPE. The improved strength and barrier properties of nanopaper achieved at lab and pilot scale mechanical refining process promises a sustainable alternative to conventional packaging. GRAPHICAL ABSTRACT: [Image: see text] SUPPLEMENTARY INFORMATION: The online version contains supplementary material available at 10.1007/s10570-022-04563-0.