Hydrophobic, moisture resistant and biorenewable paper coating derived from castor oil based epoxy methyl ricinoleate with repulpable potential

After ban on single-use plastics, completely bio-based coating on paper is in great demand to replace the plastics liner and other organic-inorganic hybrid coating. To resolve the issues like moisture, hydrophilicty and repulpability after use, a green, sustainable and hydrophobic bio-coating material for paper substrate has been developed. In this work, silanized castor oil (SCO) and silanized methyl ricinoleate (SMR) bio-resins are synthesized by structural modifications of epoxidized castor oil through transesterification and silanization process, Subsequently, the silylated bio-resins are hydrolysed and subjected to crosslinking with cellulosic paper substrate through condensation process. The coated papers showed hydrophobicity with water contact angle (WCA) up to 97° and strongly moisture resistant (moisture content of 2–3%) nature. Scanning electron microscopy analysis with energy dispersive X-ray spectra confirms the uniform coating of SMR resin with better texture and higher degree of silane grafting. The water vapor transmission rate (WVTR) decreased by 77.5% after coating because of blockage of pores and strong bonding with the cellulosic fibers. Further the coated papers showed adequate thermal stability and better tensile strength for commercial packaging. These coatings are removed by exposing to strong alkali solution at 90 °C and the recyclability potential of the paper is confirmed for reuse. These renewable resourced and eco-friendly coating materials are found to be suitable alternative for paper packaging and other coating applications with circular economy approach.