Vol.:(0123456789) 1 3 Biomass Conversion and Biorefinery https://doi.org/10.1007/s13399-022-03241-2 REVIEW ARTICLE Bio‑based materials for barrier coatings on paper packaging Praveen Kumar Kunam 1  · Dakuri Ramakanth 2  · Konala Akhila 1  · Kirtiraj K. Gaikwad 1 Received: 3 July 2022 / Revised: 16 August 2022 / Accepted: 19 August 2022 © The Author(s), under exclusive licence to Springer-Verlag GmbH Germany, part of Springer Nature 2022 Abstract  Research into alternative packaging materials is becoming more and more popular as a result of growing eco-friendly concerns regarding the usage of some petroleum-based polymeric packaging materials and coatings, as well as growing buyer demands for products with nutritious quality and extended shelf lives. Barrier coatings made of naturally renewable biopolymers can be applied to paper packing materials. These biopolymer coatings have the potential to replace the cur- rent synthetic paper and paperboard coatings, are strong oxygen and oil barriers, and may prevent the unintended moisture transfer in food goods. An appealing method of controlling the growth and spread of microorganisms in food packaging is the integration of antimicrobial compounds into coatings to create active/functional paper-based packaging materials. Here, in this review of the oxygen/moisture barrier, mechanical, and other characteristics of paper coated with bio-based materi- als. Examples are used to discuss the current and future uses of bio-based material coatings on paper packaging materials to improve barrier performance. Keywords Moisture · Oxygen · Barrier · Paper packaging · Properties · Sustainable coating · Biopolymers 1 Introduction Nowadays, it is evident that consumer acceptance has been increasing in terms of the usage of sustainable packaging materials in the food packaging sector, and they are will- ing to spend a bit higher amount for sustainable packaging materials over traditional packaging materials [1–3]. The usage of petroleum-based products over the last fve dec- ades created an impact on the planet that is irreplaceable and unrecoverable. Scientists and researchers are thriving for alternative bio-based sustainable resources to replace petroleum-based packaging materials. One such alternative packaging material is paper. Paper is a bio-based, recycla- ble, and biodegradable material generally available as a thin sheet made of cellulosic fbers [4]. It is a highly suitable material for addressing sustainable and eco-friendly packag- ing issues [5]. Researchers from the Institute of Energy and Environment, Germany, revealed that paper-based packaging has a lower impact on the environment than other traditional materials. Non-biodegradable packaging has a considera- ble impact on the environment in the form of landflls and marine debris, and such issues can be tackled by paper-based packaging. Recently, paper-based packaging gained popular- ity over other materials because of its eco-friendly nature [6]. According to a survey conducted by Cone Communica- tions, over 70% of consumers are looking for sustainable packaging options while shopping. Moreover, consumers are ready to pay 10% extra cost for the brands providing sustain- able packaging materials [7, 8]. Packaging is a highly diversifed global industry, espe- cially claiming the highest stake in the food packaging sector [9, 10]. During the COVID-19 pandemic, packaging paper consumption increased by 2.1%, and sanitary and house- hold paper increased by 3.1% in Europe [11, 12]. To replace petroleum-based packaging materials, regulating bodies are imposing restrictions on the usage of such packaging mate- rials. On the other hand, rising customer awareness creates demand for sustainable packaging. Paper-based packaging industry growth is on par with manufacturing because most products require secondary, tertiary, and quaternary packag- ing for transporting [13, 14]. Even though paper-based packaging provides strength to the core packaging, due to its porous structure, it possesses * Kirtiraj K. Gaikwad kirtiraj.gaikwad@pt.iitr.ac.in 1 Department of Paper Technology, Indian Institute of Technology Roorkee, 247667 Roorkee, India 2 Department of Polymer and Process Engineering, Indian Institute of Technology Roorkee, 247667 Roorkee, India