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The rapid growth of coating technology is impacting industries by offering novel solutions that improve product performance while addressing sustainability. Among these improvements, sustainable coatings for textiles, food packaging, and glass have emerged as important contributors to lowering environmental impact and increasing everyday material functionality and safety. This article investigates cutting-edge innovations in sustainable coating technologies and their applications in these essential sectors.
The textile industry extensively uses coatings to acquire desirable properties such as water resistance, flame retardancy, and anti-microbial features. However, conventional textile coatings can release harmful substances during production and use. Safe and Sustainable by Design (SSbD) coatings in textiles are designed to eliminate or significantly reduce these risks. Such textiles are made from biodegradable or bio-based sources, ensuring minimal environmental impact [1].
One of the key innovations in SSbD textile coatings is the development of water-repellent features while avoiding the use of per- and polyfluoroalkyl substances (PFAS). PFAS are known for their persistence in the environment and potential health risks, including concerns over accumulation in living organisms and potential links to various health issues. To address these concerns, SSbD coatings employ alternative technologies, such as non-fluorinated or bio-based materials, which provide effective water repellency without the environmental and health drawbacks associated with PFAS [2].
Additionally, SSbD flame-retardant coatings in textiles utilise safer alternatives to brominated compounds, which are toxic and harmful. Phosphorus-based compounds are now being incorporated in these coatings to meet safety standards while ensuring health protection. These innovations in SSbD coatings for textiles demonstrate a strong commitment to reducing the environmental impact and enhancing the safety of textile products [1].
The adoption of SSbD coatings in the textile industry brings multiple benefits. Firstly, the environmental safety of these coatings is significantly improved. By reducing the release of harmful chemicals, SSbD coatings help protect natural ecosystems and reduce the textile industry’s overall environmental footprint. Secondly, the health protection offered by non-toxic materials ensures that consumers are not exposed to harmful substances through their clothing. Substances used in the synthesis phase, as well as during dyeing and washing operations, can be considered toxic, especially because of the sulfur, azoic and chloric chemicals they consist of [3]. This is particularly important for products such as clothes that are in direct contact with the skin.
For this reason, the sustainability of SSbD coatings is a key advantage. These coatings are often biodegradable, which means they break down naturally without leaving harmful residues. This facilitates recycling processes and reduces waste, contributing to a more sustainable lifecycle for textile products. The integration of SSbD principles in textile coatings aligns with global sustainability goals and addresses growing consumer demand for eco-friendly products. By prioritising both safety and sustainability, the textile industry can achieve significant advancements in product quality and environmental responsibility [4].
Food-packaging materials often require coatings to provide barriers against moisture, oxygen, and contaminants. Traditional coatings can introduce harmful chemicals into food products, raising serious health considerations. SSbD coatings for food packaging are designed to be safe for direct contact with food and are often derived from natural sources.
One of the significant innovations in SSbD food-packaging coatings is the development of barrier coatings using materials such as polylactic acid (PLA) or cellulose. Unlike synthetic polymers like polyethylene (PE), which are not biodegradable, these materials provide effective barriers while being compostable [5]. Another notable innovation is the use of natural substances like essential oils in antimicrobial coatings. These coatings help extend the shelf life of food products while being safe for consumption [6]. Additionally, SSbD edible coatings made from ingredients like proteins, lipids, or polysaccharides can be applied directly to food products. These edible coatings enhance shelf life and safety without generating packaging waste, aligning with sustainability goals [7].
On the other hand, food packaging machinery coatings are also commonly needed as they lead to reduced cycle times, minimised product loss from adherence, optimised transport of raw materials, ease of cleaning, and extended lifespan of components exposed to corrosion. In particular, Teflon® and fluoropolymer coatings offer significant advantages when used on packaging machinery components. Their key properties, such as nonstick surfaces and resistance to heat and abrasion, make them perfect for parts utilised in packaging production machinery [8]. Although Teflon® and fluoropolymer coatings present some advantageous properties when used in food packaging machinery, it is essential to consider sustainable and safer alternatives, even for metal components that come into contact with the packaging. Replacing Teflon® in such applications can involve the use of advanced, non-fluorinated coatings. By transitioning to these alternative coatings, manufacturers can maintain the performance benefits of non-stick and heat-resistant surfaces while aligning with the growing demand for environmentally friendly and safe manufacturing practices.
The benefits of SSbD coatings in food packaging are substantial. Consumer safety is greatly enhanced as these coatings prevent chemical contamination of food. The use of sustainable materials in SSbD coatings also reduces the environmental footprint of food packaging, addressing both ecological and health risks. Furthermore, these coatings comply with high safety standards and regulations, ensuring compliance and establishing consumer trust. By using SSbD coatings, the food packaging industry can provide safer, more sustainable products that meet the changing needs of ecologically concerned consumers [9,10].
In particular, in previous studies [11], the application of the novel PFAS-free anti-sticking coating for bakery molds demonstrated a more positive impact on sustainability and safety compared to the conventional Teflon, with both coatings offering similar functionality. While the PFAS-free option showed benefits across most life cycle stages, the End-of-Life stage emerged as a potential area for further investigation. Similarly, new active food packaging developed with nano-drops of essential oil anchored to the surface of nano clays and encapsulated in a polymeric film showed greater sustainability and safety benefits over its traditional LDPE counterpart.
In the glass industry, SSbD coatings have introduced safer and more sustainable solutions. UV protection coatings, for instance, have moved away from using harmful substances like titanium dioxide nanoparticles. Instead, they utilise organic UV absorbers that do not pose risks to health or the environment [12]. Anti-reflective coatings, which improve visibility and efficiency in solar panels and windows, now use materials like silicon dioxide. This material is abundant, non-toxic, and effective [13]. Additionally, SSbD self-cleaning coatings use photocatalytic ingredients such as doped titanium dioxide, which are both effective and environmentally friendly, as opposed to traditional self-cleaning coatings, which may produce toxic chemicals [14].
The use of SSbD coatings in the glass sector has numerous benefits. These coatings increase the durability and performance of glass items, resulting in a longer lifespan and improved functionality. By eliminating harmful components, SSbD coatings ensure the health and safety of users. Furthermore, the use of ecologically friendly manufacturing techniques and materials corresponds with sustainability objectives, lowering the glass industry’s environmental effect. The use of SSbD principles in glass coatings displays a dedication to both innovation and environmental responsibility, resulting in a safer and more sustainable industry [15,16].
PROPLANET is at the forefront of the textile industry, developing crosslinked biopolymer oil/wax microcapsules within a polysaccharide matrix. These revolutionary coatings are hydrophobic and oleophobic, ensuring water and stain resistance without the use of hazardous PFAS.
In the food packaging machineries industry, PROPLANET is developing hybrid siloxane biobased coatings, which are intended to be nonstick and anticorrosive, ensuring food safety and increasing shelf life. The use of bio-based ingredients assures that the coatings are eco-friendly and degrade more quickly, lowering the environmental impact of food packaging waste.
PROPLANET is also developing hybrid siloxane coatings for the glass industry that are both anti-soiling and anti-reflective. These coatings enhance the durability and clarity of glass products, making them appropriate for a variety of applications such as solar panels and architectural glass. These coatings help to make the glass sector more sustainable by lowering the environmental impact of manufacturing and maintenance. The anti-soiling features reduce the need for regular cleaning, while the anti-reflective properties improve the efficiency of solar panels.
IDENER RESEARCH & DEVELOPMENT AGRUPACION DE INTERES ECONOMICO
Calle Earle Ovington 24-8, La Rinconada Sevilla, 41300, ES
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Funded by the European Union under the GA no 101091842. Views and opinions expressed are however those of the author(s) only and do not necessarily reflect those of the European Union or HaDEA. Neither the European Union nor the granting authority can be held responsible for them.
Funded by the European Union under the GA no 101091842. Views and opinions expressed are however those of the author(s) only and do not necessarily reflect those of the European Union or HaDEA. Neither the European Union nor the granting authority can be held responsible for them.
IDENER RESEARCH & DEVELOPMENT AGRUPACION DE INTERES ECONOMICO
Calle Earle Ovington 24-8, La Rinconada Sevilla, 41300, ES
Ask for more
info@proplanet-project.eu
Funded by the European Union under the GA no 101091842. Views and opinions expressed are however those of the author(s) only and do not necessarily reflect those of the European Union or HaDEA. Neither the European Union nor the granting authority can be held responsible for them.
© Copyright 2024 by EXELISIS
© Copyright 2024 by EXELISIS IKE
