Forming architectured paper by printing a starch patterned grid: a new low-cost approach for lightweighting packaging

To meet the environmental challenges, the use of plastic packaging must be drastically reduced. Paper-based solutions may be a credible alternative provided that their production cost is reduced. One way may be to improve the paper stiffness to weight ratio. In this work, a simple and low-cost approach is proposed, which consists in printing a patterned grid of starch at the paper surface by using a widespread printing process. With only a small quantity of starch (7 g/m²), the bending stiffness of a packaging paper of 60 g/m² was multiplied by more than a factor three. This improvement originates from the permanent 3D shape the paper unexpectedly took after printing. The printed lines formed “valleys” whereas the unprinted zones were raised, forming “mountains”. Drying shrinkage of the starch is assumed to play a major role, in particular by inducing local buckling of the unprinted zones. In addition, the resulting 3D shape could be interestingly tuned by adjusting the grid pattern. Even if a better understanding is necessary to be able to well control the phenomena, this approach appears relevant to form “architectured” papers with improved bending resistance to weight ratio.