The Elements of Innovation Discovered

Graphene lends strength to food packaging

Metal Tech News - May 30, 2025

Say goodbye to plastic, forever chemicals, and flimsy paper plates; hello to stronger and more sustainable paper products.

Scientists from Northwestern University's McCormick School of Engineering have tapped into the superlative properties of graphene to develop water- and oil-resistant coatings that strengthen paper-based food packaging while offering a safer, more sustainable alternative to plastic and forever chemicals.

This market-ready innovation from GO-Eco, a startup out of Northwestern's Querrey InQbation Lab (The Q), could help transform a food packaging sector that generates more than $60 billion in annual sales in the U.S. alone, much of it relying on coated paperboard and corrugated cardboard.

To make these products leakproof and durable, manufacturers typically coat them with plastic, foil, or PFAS – per- and polyfluoroalkyl substances known as "forever chemicals" due to their persistence in the environment. While effective, these coatings are increasingly under regulatory scrutiny due to potential health risks and environmental harm.

The solution developed by GO-Eco builds on the remarkable qualities of graphene, a material made from one-atom-thick layers of carbon that is renowned for its strength, elasticity, and impermeability.

angellodeco at stock.adobe.com

Graphene is a material made from one-atom-thick layers of carbon arranged in a hexagon pattern that is renowned for its superior conductivity, strength, elasticity, and other properties.

By leveraging graphene oxide – a modified form of graphene that disperses easily in water – the GO-Eco coating adds strength and moisture resistance to paper products without introducing toxic or persistent chemicals. And because it's carbon-based, the coating is both biodegradable and non-toxic.

"This is not just a materials innovation; it's a market-ready solution," said Timothy Wei, an adjunct professor of mechanical engineering at Northwestern and co-developer of the technology. "We are thrilled to be taking GO-Eco from the lab to the factory floor, with applications that could ultimately transform the entire food packaging industry."

Wei, who has deep expertise in food industry manufacturing, teamed up with SonBinh Nguyen, a professor of chemistry at Northwestern's Weinberg College of Arts and Sciences and an expert in graphene chemistry, to develop the new coating.

Rigorous testing of the graphene oxide coating has shown that it improves both barrier performance and paper strength by 30 to 50% compared to conventional coatings. Prototype testing has included paper plates, cups, straws, plastic produce bags, and cardboard boxes.

With pilot-scale testing conducted at Western Michigan University's Paper Pilot Plant, GO-Eco is now pursuing FDA food-contact approvals and is certifying the recyclability and compostability of its graphene-enhanced products.

Backed by a major national tableware manufacturer and support from additional industry partners, the company is preparing to scale up production and move into commercial manufacturing.

If successful, this graphene oxide coating could offer more durable paper products without the downsides of plastic and PFAS – a win for both consumers and the environment.

Author Bio

Shane Lasley, Metal Tech News

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With more than 17 years of covering mining, Shane is renowned for his insights and in-depth analysis of mining, mineral exploration, and technology metals.

 
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