2025 TAPPI Aqueous Barrier Coating for Paper and Paperboard Course

Tentative Course Schedule (2.5 Days)

Downloadable Schedule

DAY 1

1. Introduction to Barrier Coating and Sustainability
   • Why barrier coating
   • Issues with the conventional barrier coatings – regulatory (health and environment), recyclability and compostability
   • Issues with single use plastics
   • Sustainability goals
   • Aqueous barrier coating
     
     
2. Barrier coating mechanisms and fundamentals
   • Two approaches to barrier coatings - physical barrier & chemical barrier
   • Transport mechanism through barrier coatings
   • Key differences between liquid barrier coatings and vapor barrier coatings
   • Overview of polymer barrier performance metrics
     
     
3. Barrier requirements for different market segments
   • Key market segments / short term versus long term barrier requirements
   • Special considerations for food contact barrier coatings
   • Fit of barrier coated fiber-based articles to replace alternative barrier packaging
     
     
4. Barrier Coating Test Methods
   • Oil & Grease (3 M Kit and others)
   • Water Resistance (Cobb 30/Cobb60)
   • Water Vapor Transmission Rate
   • Oxygen Transmission
   • Heat seal
   • Blocking
     
     
5. Barrier Coating Test Methods Demo at Applied Testing Lab (Atlanta)
   
   

DAY 2

1. Materials for Barrier Coatings
• Pigments
• Synthetic binders
• Biobased materials
• Nano/microfibrillated Cellulose (NFC/MFC)
• Additives
  
  
2. Paper and Paperboard Substrates for Packaging
• Overview of paper and paperboard substrates
  
  

Sustainability considerations in choice of substrate

1. Barrier Coating Formulations
   • Additives and Optimization of Barrier Coating Formulations
   • Single vs Multilayer barrier coatings
   • Coating Preparation
     
     
2. Barrier Coating Rheology and Application Methods
   • Blade Coating
   • Rod Coating
   • Curtain Coating
   • Rotogravure and Flexographic Presses
   • Drying of Barrier Coatings
     
     

DAY 3 (half day)

1. Coating Defects and Fold Cracking issues
• Common types of coating defects
• Ways to detect coating defects
• Ways to mitigate coating defects
  
  
2. Q&A with instructor and Open Discussion

Dr. Prakash Malla

Prakash Malla retired in early 2024 as Director of Research & Development at Thiele Kaolin Company, Georgia, after a distinguished career spanning nearly 32 years. During his tenure, he made substantial contributions to both applied and fundamental research on kaolin minerals—including calcined clay—resulting in improved products and processes, primarily in the area of paper and paperboard coating. In addition to leading a multidisciplinary team of scientists, engineers, and technicians, Prakash was instrumental in advancing technologies in kaolin brightness enhancement, particle size engineering, viscosity and dispersion optimization, coating formulation development and design for performance improvement and cost savings. His expertise also extended to providing high-level technical support to customers. He is currently President of Quantum Industrial Minerals, an independent consulting firm focused on mineral-based materials and applications. He earned his Ph.D. in Clay Mineralogy and Clay Chemistry from Rutgers University and completed a five-year postdoctoral fellowship in materials science at Pennsylvania State University. At Penn State, his research involved the development of advanced dehumidifying microporous and nanoporous materials using intercalated clays, silica gels, and zeolites for adsorbent-based cooling system applications. An active member of TAPPI for 33 years, Prakash has held numerous leadership roles, including Chair of the Coating Division (now known as the Coating, Printing, and Surface Enhancement—CPSE—Division). He received the CPSE Divisional Leadership Award in 2014, the Technical Award in 2025, and was elected a TAPPI Fellow in 2018. In 2024, Prakash served as editor of the newly published TAPPI book Pigments for Paper and Paperboard. He currently sits on the editorial boards of the Journal of Porous Materials and Clays & Clay Minerals. Prakash holds 17 U.S. patents and has authored and coauthored nearly 50 peer-reviewed technical papers, including several book chapters.

Dr. John Roper

John Roper received his BS in chemistry from Furman University and his PhD in chemistry from the University of Chicago.  John then joined the Dow Chemical Company where he worked for over 35 years doing research related to paper and architectural coatings.  John became a Research Fellow at Dow before retiring in 2018 and now works as an independent consultant.  John has been very active in TAPPI starting as a member on the Coating and Graphic Arts Division (CG&A) Technical Program Committee (TPC) followed by progression through the CG&A Leadership positions. In addition, John served as an editor of the TAPPI Journal, as an organizer of multiple TAPPI short courses, and as a member of the Advanced Coatings Fundamentals Symposium TPC.  He has received numerous external recognitions of his work including being named a TAPPI Fellow in 2004, winning the Charles Engelhard Medallion for Technical Leadership from the CG&A Division of TAPPI in 2012; winning the CPSE Division Leadership and Service Award sponsored by Omya in 2024; winning the CPSE Division Mentoring and Education Award sponsored by Smurfit Westrock in 2025.  John is also an inventor on 22 US patents and the author/coauthor of over 90 external papers/presentations.

Cancelation Policy: If you find that you have to cancel, your full registration fee will be refunded if TAPPI’s Registration Department receives written notification (fax acceptable at  +1.770.209.7206 by  (Sept. 9, 2025).  Please note:  There will be a 50% refund for all written cancellations made after (Sept. 9, 2025) but no later than 5 business days prior to the start of the course (October 2, 2025).  Understandably, after (October 2, 2025)no refunds can be issued.  Substitutions, however, will be accepted any time without a penalty

• 50% Refund After Sept 9, 2025
• 50% Refund Before Oct 2, 2025
• No Refund After Oct 2, 2025

TAPPI offers discounted pricing on TAPPI Press publications for Course attendees. Purchase with registration and receive a 15% discount (discount already applied to price at check out). Pick-up onsite and save on shipping.

These titles have been selected just for this event:

1. NEW! Pigments for Paper and Paperboard

This book compiles the most comprehensive information on nearly every pigment used in paper coating and filling. This text will enable the reader to understand the fundamental properties of these materials and how these properties are utilized to achieve the desired performance attributes and cost effectiveness. 

2. The Coating Processes

This book covers fundamentals and practical applications of paper coating. The book is divided into eight chapters that outline the process of making coated paper, the preparation, application and drying, and treatment of the dried coated surface.                       

3. Starch and Starch Products in Surface Sizing and Paper Coating

This book is a comprehensive overview about basic starch chemistry, starch modifications, quality control, shipment, storage, cooking, in-mill conversion, best practices of application in surface sizing and coating, and also includes the environmental aspects. 

4. The Sizing of Paper, 3rd. Ed.

This edition reflects the experiences and technologies that have developed with new applications, converting to neutral or alkaline pH wet end conditions.  There are 17 chapters on topics like the chemistry of aluminum, soap size vs. dispersed size, fluorochemical sizing, and surface sizing additives, to name a few. The size press surface sizing section is expanded from the last edition to accommodate the new interest generated by the technology. 

5. Binder Migration in Paper and Paperboard Coatings

Nonuniform binder distribution along the surface of coated paper, called binder migration, is a problem that has plagued the papermaking and printing industries for years. This book offers a fundamental understanding of binder migration. It also covers how binder migration happens, what factors cause or influence it, strategies to use in controlling it, and how binder migration affects printing and gluing.

6. Handbook for Pulp and Paper Technologists, 4th Ed. (SMOOK)

The Handbook For Pulp and Paper Technologists (The SMOOK Book), is by far the best-selling text to introduce the entire technology of pulp and paper manufacture. The major objective of the fourth edition was to provide a readable, up-to-date, comprehensive textbook. The book features 27 chapters covering all aspects of pulping and papermaking. 

7. Paper Coating Additives

This work contains in-depth coverage of nearly all major additives used in paper coating. Each chapter was written by a specialist in his/her field, and reviews chemistry, applications, and end use of each class of coating additive. An excellent reference source, this text reviews past coating industry technology and incorporates current knowledge in the field.

8. *Pigment Coating and Surface Sizing of Paper, 2nd Ed.

Volume 11 of the Papermaking Science and Technology Series, published by the Finnish Paper Engineers’ Association. The second edition is intended to serve as a text and handbook for pigment coating and surface sizing technologies.   This is also an excellent textbook resource for universities and colleges. This series is ideal to train new employees at your company or as a reference guide for your experienced workforce.