NPCS has been helping entrepreneurs, startups, MSMEs, and industrial investors since 1992 with detailed project reports, feasibility studies, market research, and business consulting services across 50+ industries.
A water-based emulsion is a complicated coating system that incorporates polymers into a hydrous medium instead of organic solvents. This system uses water’s solvent characteristics to create a homogeneous and stable emulsion that dries to a strong, protective coating. The type of polymers is subject to change in these emulsions. It is common to use styrene-acrylic, acrylic and polyurethane dispersions in these emulsions due to their adhesion and moderate character to the environment.
When water-based emulsion coatings are applied to a substrate, generally cardboard or paper, water evaporates. After the H2O evaporates, the dispersed polymer particles aggregate and a continuous film is formed that coats the substrate and forms a barrier. This barrier is resistant to moisture, oil, and grease. The technique is useful for the production of packaging materials that are resilient and able to withstand the challenges of food packaging.
Benefits
There are a range of functional and ecosystem benefits (in comparison to PE coatings) of using water-based emulsions in the coating of paper cups and straws. We examine these benefits and offer a list of the major benefits.
Biodegradability and compostability: Water-based emulsions can be completely biodegraded and composted in a way that PE coatings can’t. Hence, products in the papers covered using the mentioned food emulsions can completely biodegrade leading to less trash in the landfill and to a gentler (and more) solution for disposal.
Recyclability: The introduction of water-based coatings potentially boosts the recyclability of paper goods. The coatings and linings of paper straws and cups that are made of polyethylene (PE) are not recyclable. The polyethylene coating has to be deconstructed from the paper goods, which is often a costly process. Water-based, PE coatings, are more readily designed to dissolve in the recycling process, aiding the recovery and reuse of paper pulp in the recycling process.
Less Environmental Impact: Water-based emulsions offer a more plentiful environmental experience compared to PE coatings. Water-based emulsions also improve indoor air quality and decrease the risk of health problems for workers in manufacturing facilities because they do not release any volatile organic compounds (VOCs) during the manufacturing process and application.
Safety and Non-Toxicity: Water-based emulsions release fewer threats to human health. Being the safe option for food packaging, these emulsions are made of water and naturally produced polymers. This is of increased importance with the food and beverage packaging in water-based, food friendly polymers paper cups and straws.
Performance and Functionality: Innovations in water-based technology have also produced emulsions that are on par with, or offer greater technology advancements, compared to traditional PE coatings. The Innovative Water-based Emulsions PE can offer the paper-based cup and straws improved strengths against liquid and vapor permeation, enhancing their usage and function in any condition.
- Energy Efficiency: When comparing different types of coatings, peelable coatings have a more resource-heavy application than water based coatings. For the water based coatings, the application is at a much lower temperature which reduces the energy levels needed for drying and curing, thus, overall production costs are decreased and the carbon footprint is decreased.
- Application Flexibility: Since water-based coatings can be rolled, brushed, and sprayed, there is a certain element of flexibility in the manufacturing processes that can be achieved. With such flexibility, efficiency of manufacturing is greatly improved and a variety of differently sized and shaped paper products can be achieved.
- Improved Aesthetics: Paper products that have been coated using a water based coating tend to look better. Not only can the coating be changed to be more or less glossy, but the coatings can also improve the quality of print allowing for colored graphics to be printed on the paper.
The use of water-based emulsions on paper straws and cups is a helpful replacement for standard peelable coatings. The use of these methods directly responds to the demand of customers for more sustainable packaging options, and provides a practical solution to the negative effects of disposable paper products on the environment.
Forecast for India
The India paper cup market is projected to reach from 8.59 billion units to around 11.38 billion units from 2024 to 2032, representing a CAGR of 3.2%. Factors driving the paper cup market in India are convenience and the recyclability of paper cups, increasing disposable incomes, government policies, and the food services industry. In India, paper cups are used for food and beverage items like tea, coffee and soft drinks. In this industry, paper cups are categorized as hot and cold. To prevent the cup from losing its structural integrity, cold cups are lined with wax to prevent the beverage from seeping through the paper. The only difference in the paper cups' construction is that hot cups are made to withstand the heat and cold cups are not. Currently, the leading factors driving the growing disposable paper cup market are the improved hygiene and sanitary aspects.
Global Market Outlook
In 2022, the global demand for paper cups was USD 9.90 billion, and it is projected to reach USD 12.94 billion by 2030 with a CAGR of 3.1%. The demand for paper cups to serve coffee, tea, soup, and other beverages is likely to grow from USD 10.43 billion in 2023. Disposable food service items with custom print wrappers of the same brands are preferred by restaurants to increase food sales and promote branding. The market is being driven by the growth in demand for disposable food service items, such as paper plates, trays, utensils, and other items used in restaurants.
In an effort to support their well-publicized sustainable initiatives and expose the environmental impact of their food service operations, several restaurants and hotel customers are transitioning to paper-based products and abandoning the use of polystyrene and plastic products. They pose a potential new source of demand for the paper cup industry. Additionally, to improve the use of recycled paper in their products, several paper manufacturers have built new recycling units in their mills. These efforts will likely create new opportunities for expansion in the paper cup market.
Caffeine desires are increasing the trade of paper coffee cups globally. As more people opt for coffee or tea to boost their energy, paper cups are becoming an ironic part of the problem. The global paper cup market industry is also being expanded due to the demand for take out services. People are also consuming more ready-to-drink beverages. The 2023 Poll released by the National Coffee Association (NCA) shows 65% of Americans were daily coffee consumers, rising from 62% in 2020.
Some of the largest markets for the foodservice disposables, including foodservice disposables, are the U.S. (USD 2.78B) and Canada (USD 2.09B), where services related to tableware for food and consumer products packaging are predicted to reach USD 1,584.78 million in 2022, according to the Finnish consumer packaging multinational, Huhtamäki Oyj.
Conclusion
Over the past few decades, considering the shift to more eco-friendly services, launching a water-based food emulsion paper coating would allow a business to comm-ect its products with the impact-first businesses that are innovating in the packaging industry.
| Plant capacity | Plant & machinery | Working capital | Cost of Project | T.C.I | Return | Break even |
|---|---|---|---|---|---|---|
| Capacity: Acrylate Emulsions 3 MT Per Day | 55 | N/A | 414 | 28 | 54 |
Entrepreneur India, an Industrial monthly magazine on industrial development, technologies & project opportunities aims at simplifying the process of choosing the suitable project for investment.
Entrepreneur India - Copyright 2017-. All rights reserved.
