Comprehensive of PE Coating Paper

Is your food packaging truly protecting your products? Many packaging materials fail to resist moisture, grease, and heat, leading to leaks and contamination.

PE (polyethylene) coated paper solves this problem by adding a thin plastic layer to paper, making it water-resistant, greaseproof, and durable. It’s widely used in food packaging, medical supplies, and retail industries.

In this post, you’ll learn what PE-coated paper is, its key properties, and how it benefits various industries. We’ll also discuss its environmental impact and future innovations in sustainable packaging.

What is PE Coating?

PE (Polyethylene) coating is a process where a thin layer of polyethylene is applied to paper, enhancing its durability, water resistance, and greaseproof properties. This coating makes the paper suitable for food packaging, medical applications, and retail uses.

Explanation of the PE Coating Process

PE coating involves applying a thin layer of polyethylene material to paper through a process called extrusion coating. During this process:

1. Polyethylene material is heated until it becomes molten

2. The molten PE is formed into a thin film (typically no more than 0.04cm thick)

3. This hot film is pressed onto the paper surface under controlled pressure

4. The material cools to create a strong, adhesive bond between the PE and paper

5. The result is a uniform coating that's difficult to separate from the paper base

This coating process creates a protective barrier that prevents liquids from penetrating the paper, making it ideal for food packaging, beverage containers, and other applications requiring moisture resistance.

Composition of PE Coating (LDPE, HDPE)

PE coatings are primarily made from petrochemical sources derived from natural gas and crude oil. The composition varies based on the specific application requirements:

Type	Characteristics	Common Applications
LDPE (Low-Density Polyethylene)	• Lower melting point • More flexible • Excellent moisture barrier • Good heat-sealing properties	• Disposable cups • Food containers • Paper packaging for cold items
HDPE (High-Density Polyethylene)	• Higher melting point • More rigid • Stronger barrier properties • Better chemical resistance	• Industrial packaging • Heavy-duty containers • Applications requiring extra durability

LDPE is the most commonly used type for paper coating in food packaging due to its flexibility and excellent moisture-resistant properties. The manufacturing process for LDPE involves compressing monomer ethylene gas under high pressure using free radical polymerization.

How Thickness Affects PE Coating Performance

The thickness of the PE coating is measured in grams per square meter (GSM). The coating weight impacts the paper’s strength, flexibility, and barrier properties.

Coating Thickness (GSM)	Properties	Common Uses
10 GSM	Basic moisture resistance	Food wrappers, disposable tableware
12-15 GSM	Moderate strength, suitable for lamination	Paper bags, sandwich wraps
18-20 GSM	High durability, strong barrier protection	Hot drink cups, industrial applications

The thicker the coating, the stronger the paper, but it also becomes less recyclable. Industries balance thickness based on functionality and sustainability needs.

Different paper types require varying coating thicknesses—rough surfaces like kraft paper need thicker coatings to create a smooth, uniform surface, while smoother papers like white or bamboo-based varieties can achieve desired properties with thinner PE layers.

Properties of PE Coated Paper

PE coated paper is widely used in packaging due to its protective barrier properties, durability, and versatility. The polyethylene (PE) layer enhances the paper’s performance in several key areas, making it ideal for food packaging, medical supplies, and industrial applications. Below are the essential properties that define PE coated paper.

1. Water Resistance

One of the most significant advantages of PE coated paper is its waterproof barrier. The polyethylene layer prevents liquids from penetrating, making it suitable for applications where moisture protection is crucial.

✅ Benefits:

• Prevents paper from absorbing water or humidity

• Extends the shelf life of packaged goods

• Ideal for cold beverage cups, food containers, and frozen food packaging

2. Grease and Oil Resistance

PE coated paper acts as a barrier against oil and grease, ensuring that fats from food do not seep through the packaging. This property is particularly useful for fast food packaging.

✅ Common Applications:

• French fry holders, burger wraps, and pastry bags

• Snack and confectionery packaging

• Takeout containers for greasy foods

3. Heat Sealability

The polyethylene coating allows heat sealing, enabling airtight and tamper-proof packaging. This ensures freshness and hygiene for food and pharmaceutical products.

Feature	Benefits	Applications
Heat-sealable layer	Creates a strong, secure seal	Food containers, medical pouches
Airtight closure	Maintains freshness	Coffee bags, snack pouches
Tamper-evident	Ensures product safety	Sealed food packaging

4. Chemical Inertness

PE is chemically stable, meaning it does not react with food, beverages, or medical products. This ensures that the flavor, quality, and safety of packaged products remain intact.

✅ Key Advantages:

• Non-toxic and safe for direct food contact

• Does not alter taste, odor, or composition

• Complies with FDA and EU food safety standards

5. Flexibility and Durability

PE coated paper offers excellent strength and flexibility, allowing it to be folded, shaped, and handled without tearing.

✅ Why It Matters?:

• Enhances packaging integrity

• Prevents leakage or breakage

• Suitable for paper cups, food trays, and medical wrappers

6. Printability and Branding Options

PE coated paper supports high-quality printing, allowing brands to display logos, colors, and product information effectively.

Printing Option	Effect	Common Uses
Matte Finish	Soft, non-reflective surface	Luxury packaging, branding
Glossy Finish	Bright, vibrant colors	Promotional materials, labels
Digital Printing	High-resolution images	Food packaging, marketing

Types of PE Coated Paper

PE coated paper comes in various types, each designed for specific applications in food packaging, printing, and industrial uses. The type of polyethylene (PE) coating—whether single-sided, double-sided, or specialty coatings—determines its functionality. Below are the most common types of PE coated paper and their applications.

Single-Side PE Coated Paper

Single-side PE coated paper features a polyethylene layer on only one surface of the paper substrate. This configuration is:

• Primarily used for disposable food packaging containers

• Designed with the PE coating on the interior to provide moisture resistance

• Cost-effective for applications requiring protection on just one side

• Suitable for products where exterior printability is important

The single-sided design balances water resistance with economy, making it ideal for short-term food service applications like sandwich wrappers and burger boxes.

Double-Side PE Coated Paper

When both surfaces of the paper are laminated with polyethylene film, it creates double-side PE coated paper. This type offers:

• Superior moisture protection from both internal and external sources

• Enhanced durability compared to single-sided versions

• Excellent performance in cold food applications (ice cream cups, cold beverages)

• Improved structural stability when exposed to condensation

Double-sided coating prevents the packaging from becoming soggy due to environmental moisture while simultaneously containing liquids inside.

Sandwich PE Coated Paper

This specialized configuration features a layer of PE between two layers of paper, creating a three-layer composite. Benefits include:

• Exceptional water resistance

• Superior structural integrity

• Ideal for heavy-duty food packaging applications

• Perfect for items requiring extended moisture protection

Release Liner PE Coated Paper

Type	Primary Function	Key Feature	Common Applications
Release Liner	Backing material	Non-stick surface	Labels, adhesive tapes, stickers

Release liner PE coated paper incorporates a specialized coating that prevents adhesives from permanently bonding to the paper surface, allowing for easy removal when needed.

Matte PE Coated Paper

Matte PE coated paper features a non-reflective finish that:

• Reduces glare and improves readability

• Provides a sophisticated, premium appearance

• Offers excellent print definition and sharpness

• Makes labels easy to read even in bright lighting conditions

Glossy PE Coated Paper

Glossy PE coated paper delivers a highly reflective, shiny surface that:

• Enhances color vibrancy and image contrast

• Creates eye-catching packaging that stands out on shelves

• Provides a premium, high-end appearance

• Excels in applications where visual impact is crucial

Each type of PE coated paper offers unique benefits tailored to specific packaging requirements, allowing manufacturers to select the ideal material for their particular application.

PE Coated Paper vs Other Coated and Uncoated Papers

When selecting the right paper for packaging, printing, or industrial use, it's essential to compare PE coated paper with other coated and uncoated options. Factors like moisture resistance, grease resistance, durability, and printability influence the decision. Below is a detailed comparison.

Comparison of Water/Moisture Resistance

PE coated paper offers superior water resistance compared to other paper types:

Paper Type	Water Resistance	Performance When Wet	Applications
PE Coated	Excellent	Maintains structural integrity	Food containers, beverage cups
Clay Coated	Moderate	Becomes soggy when saturated	Magazines, brochures
Wax Coated	Good	Degrades with prolonged exposure	Temporary food packaging
Uncoated	Poor	Quickly absorbs water and fails	Indoor printing, stationary

The polyethylene layer creates a complete barrier against liquids, unlike other coatings that may only provide temporary or partial protection.

Difference in Grease/Oil Resistance

When it comes to handling greasy or oily substances:

Paper Type	Grease Resistance	Common Uses
PE Coated Paper	✅ Excellent	Fast food packaging, snack wrappers
Wax Coated Paper	✅ Moderate	Sandwich wraps, bakery bags
Clay Coated Paper	❌ Low	Magazines, carton packaging
Uncoated Paper	❌ None	Standard office use

This grease resistance makes PE coated paper ideal for fast food packaging where other papers would quickly fail.

Structural Integrity and Durability

PE coating significantly enhances paper's physical properties compared to alternatives:

1. Greater tensile strength than uncoated or lightly coated papers

2. Superior resistance to tearing even when wet

3. Better puncture resistance than wax or clay coated options

4. Maintains shape under stress where uncoated papers would crumple

5. Longer functional lifespan in challenging environments

This improved durability translates to better product protection and reduced packaging failures.

Printing Capabilities and Limitations

Printing on PE coated paper requires special coatings or treatments to improve ink adhesion, whereas uncoated and clay-coated papers offer better direct printability.

✅ Pros of PE Coated Paper for Printing:

• Smooth surface for vivid colors and high-resolution graphics

• Ideal for branding (cups, food packaging, labels)

❌ Limitations:

• Standard inks may not adhere well without additional coatings

• Not ideal for high-volume book/magazine printing

Paper Type	Printability	Best Uses for Printing
PE Coated Paper	✅ High (requires treatment)	Product branding, labels, food packaging
Clay Coated Paper	✅ Excellent	Magazines, brochures, high-end packaging
Wax Coated Paper	❌ Low (wax repels ink)	Limited printing, mostly food wraps
Uncoated Paper	✅ High (absorbs ink well)	Office documents, newspapers

Applications of PE Coated Paper

PE coated paper is a versatile material used across multiple industries, thanks to its moisture resistance, greaseproof qualities, and durability. It is widely utilized in food packaging, medical applications, labeling, and even specialty paper products. Below are the primary applications of PE coated paper.

1. Food Packaging

One of the most common uses of PE coated paper is in food packaging. The waterproof and grease-resistant properties make it ideal for storing hot and cold foods.

✅ Common Food Packaging Products:

• Paper Cups – Coffee, tea, soft drinks, and smoothies

• Bowls & Containers – Soups, salads, and frozen meals

• Fast Food Wraps – Burgers, sandwiches, fries, and wraps

• Bakery Packaging – Pastry bags, cake boxes

2. Medical Packaging

PE coated paper is widely used in the medical and pharmaceutical industry for packaging sterile products.

✅ Examples:

• Blister packs for pills and tablets

• Sterile pouches for surgical instruments

• Medical device packaging

3. Labels and Stickers

PE coated paper provides excellent printing surfaces for:

Application	Benefits	Common Uses
Product Labels	Water resistance, durability	Food labels, beverage bottles
Stickers	Adhesion strength, weather resistance	Outdoor applications, packaging
Printing Papers	Vibrant color reproduction	Magazines, brochures, promotional materials
Marketing Materials	Professional appearance	Catalogs, product sheets, flyers

4. Printing Papers

PE coated paper supports high-quality printing, making it useful for advertising and branding.

✅ Best Uses:

• Magazines, brochures, and promotional materials

• High-resolution product packaging

5. Specialty Papers (Maps, Plans, Signage)

PE coated paper is used to produce water-resistant documents such as maps, construction plans, and outdoor signage.

Specialty Paper Type	Primary Use
Waterproof Maps	Outdoor activities, hiking, navigation
Construction Plans	Architecture, engineering blueprints
Weatherproof Signage	Outdoor advertising, retail displays

6. Wrapping Paper and Gift Packaging

PE coated paper is durable and visually appealing, making it a great choice for gift wrapping and premium packaging.

✅ Uses:

• Gift wrap for luxury products

• Retail shopping bags

• Branded merchandise packaging

7. Textiles and Wearables

PE coated paper is sometimes used in clothing applications, particularly for temporary protective coatings on textiles.

✅ Industries:

• Industrial protective wear

• Disposable aprons and medical gowns

8. Wallpaper

PE coated paper is commonly used in wallpaper production, offering a durable and easy-to-clean surface.

✅ Benefits:

• Moisture-resistant for kitchens and bathrooms

• Custom printing for unique interior designs

9. Bookbinding

High-quality PE coated paper is used for bookbinding and hardcover production, ensuring durability and water resistance.

10. Arts and Crafts

PE coated paper is a favorite in the crafting industry, especially for scrapbooking, origami, and DIY projects.

11. Retail Packaging

Retail brands use PE coated paper to enhance product presentation while ensuring strength and protection.

✅ Examples:

• Electronics packaging

• Luxury cosmetics boxes

12. Disposable Tableware

PE coated paper is used in making single-use plates, cups, and bowls for restaurants, cafeterias, and events.

✅ Why It’s Popular?:

• Lightweight yet strong

• Grease-resistant and disposable

Disadvantages of PE Coated Paper

While PE coated paper is widely used for food packaging, labeling, and industrial applications, it has certain limitations and drawbacks, particularly regarding recycling, environmental impact, and cost. Below are the key disadvantages of PE coated paper.

Limited Oxygen and Gas Barrier Properties

Despite excellent water resistance, PE coating offers poor protection against:

• Oxygen penetration

• Carbon dioxide permeability

• Other gases that can affect product freshness

• Aroma compounds that can escape packaging

This limitation makes PE coated paper unsuitable for applications requiring extended shelf life or complete gas impermeability.

Poor Odor Barrier

PE coating provides minimal protection against odors:

• Allows aromas to escape from packaged products

• Permits external odors to affect product quality

• Cannot maintain fragrance integrity long-term

• May require additional packaging layers for odor-sensitive items

Recycling Challenges Requiring Special Processing

The recycling process for PE coated paper is significantly more complex than for uncoated paper:

Recycling Challenge	Description	Impact
Hydro Pulping Requirement	Special equipment needed to separate PE from paper fibers	Increased recycling costs
Limited Facilities	Fewer recycling centers accept PE coated materials	Reduced recycling rates
Separation Difficulty	Strong adhesion between PE and paper makes separation challenging	Higher processing expense
Contamination Concerns	PE residue can affect paper recycling quality	Lower-grade recycled material

Not Biodegradable or Compostable

Environmental persistence is a significant concern:

1. PE coating is not naturally biodegradable

2. Can persist in the environment for hundreds of years

3. Not suitable for composting facilities

4. Contributes to long-term landfill accumulation

Additional Limitations

PE coated paper faces several other challenges:

• Higher cost than uncoated alternatives, increasing packaging expenses

• Printing difficulties requiring specialized inks and techniques for optimal adhesion

• Limited heat resistance (typically 80-100°C) restricting use in microwave or high-temperature applications

• Environmental concerns from petroleum-based production and waste disposal impacts

Quality Control and Testing of PE Coated Paper

Ensuring the quality, safety, and performance of PE coated paper requires strict quality control measures throughout the manufacturing process. From raw material selection to final product testing, manufacturers follow international standards to ensure product consistency and compliance. Below are the key aspects of quality control and testing for PE coated paper.

1. Importance of Raw Material Inspection

Quality control starts with inspecting raw materials to ensure the paper base and polyethylene coating meet required specifications.

✅ Key Checks:

• Paper Quality – GSM (grams per square meter), smoothness, and fiber composition

• Polyethylene Coating – Thickness, grade (LDPE/HDPE), and heat resistance

• Adhesion Properties – Ensuring proper bonding between paper and PE layer

Using high-quality raw materials reduces defects, waste, and performance issues in the final product.

2. Process Control During Manufacturing

The PE coating process requires continuous monitoring of critical parameters:

1. Extrusion temperature profile - Controls coating uniformity

2. Application pressure - Ensures proper adhesion

3. Line speed - Affects coating thickness

4. Cooling rate - Influences crystallization and surface properties

5. Tension control - Prevents wrinkles and dimensional variations

Monitoring these parameters throughout production helps identify and correct issues before they affect product quality or create excessive waste.

3. Finished Product Testing Methods

After production, PE coated paper undergoes multiple tests to check performance and durability.

3.1 Water Resistance Test

This test evaluates the paper’s ability to resist water absorption.

✅ Test Method:

1. Place a water droplet on the coated surface.

2. Observe if absorption, beading, or penetration occurs.

3. Measure the time taken for water to break through the PE layer.

Performance Level	Water Resistance
Excellent	No absorption, water beads on surface
Moderate	Slow absorption over time
Poor	Immediate penetration

3.2 Grease Resistance Test

Measures the paper’s ability to block oil and fats from passing through.

✅ Test Procedure:

• Apply oil or grease to the PE coated surface.

• Observe if stains or leaks appear on the uncoated side.

• Rank performance using Kit Test Ratings (scale of 1-12).

✅ Applications:

• Fast food wrappers, snack packaging, and bakery bags require high grease resistance.

3.3 Tensile Strength Test

This test assesses paper durability and resistance to tearing under force.

✅ Key Testing Steps:

1. Cut standard-sized samples of PE coated paper.

2. Apply gradual force until the sample tears.

3. Measure tensile strength in Newtons per millimeter (N/mm).

Grade	Tensile Strength (N/mm)	Recommended Use
High	Above 20 N/mm	Heavy-duty food trays, labels
Medium	10-20 N/mm	Cups, sandwich wraps
Low	Below 10 N/mm	Light packaging

4. Industry Standards and Regulations

Multiple regulatory frameworks govern PE coated paper quality and safety:

• FDA Regulations (USA)

• 21 CFR 177.1520 - Polyethylene specifications

• 21 CFR 176.170 - Components for paper in food contact

• Food Contact Notification (FCN) requirements

• Migration testing protocols

• ASTM Testing Standards

• ASTM D779 - Water resistance of paper

• ASTM D828 - Tensile properties

• ASTM F119 - Rate of grease penetration

• ASTM D3776 - Basis weight measurement

• European Regulations

• Regulation (EC) No 1935/2004 - Materials in contact with food

• Regulation (EU) No 10/2011 - Plastic materials in food contact

• EFSA safety assessments and opinions

• Migration limits and testing methodologies

Compliance with these regulations is essential for manufacturers, particularly those producing PE coated paper for food packaging applications. Quality control systems must document testing results and maintain traceability throughout the production process.

Conclusion

PE coated paper offers water resistance, grease protection, durability, and printability, making it ideal for food, medical, and industrial uses.

Choosing the right coating ensures optimal performance in packaging, labeling, and specialty applications while maintaining product integrity.

Balancing functionality, cost, and sustainability is crucial as industries shift toward eco-friendly alternatives for a greener future.