DESC:
Field of the invention
The present invention relates to packaging materials. More specifically the present invention relates to plastic-free and or biodegradable sealing composition with improved performance (water resistance, sealability, oil and Grease resistance), and re-pulpable.

Background and the prior art
Materials such as paper, paperboard, plastic, polystyrene, and even metals are presently used in enormous quantity in the manufacture of articles such as containers, separators, dividers, lids, tops, cans, and other packaging materials. Modern processing and packaging technology allows a wide range of liquid and solid goods to be stored, packaged, and shipped in packaging materials while being protected from harmful elements, such as gases, moisture, light, microorganisms, vermin, physical shock, crushing forces, vibration, leaking, or spilling. Many of these materials are characterized as being disposable, but actually have little, if any, functional biodegradability. For many of these products, the time for degradation in the environment can span decades or even centuries.

Packaging materials (e.g., paper, paperboard, plastic, polystyrene, glass, or metal) are all, to varying extents, damaging to the environment. For example, the manufacture of polystyrene products involves the use of a variety of hazardous chemicals and starting materials, such as benzene (a known mutagen and a probable carcinogen). Chlorofluorocarbons (or “CFCs”) have also been used in the manufacture of “blown” or “expanded” polystyrene products. CFCs have been linked to the destruction of the ozone layer.

Due to widespread environmental concerns, there has been significant pressure on companies to discontinue the use of polystyrene, PE coated paper and paperboard products in favor of more environmentally safe materials. Some groups have favored the use of products such as paper or other products made from wood pulp. However, there remain drawbacks to the sole use of paper due to the tremendous amount of energy that is required to produce it. A strong need to find new, easily degradable materials that meet necessary performance standards remains.

Degradability is a relative term. Some products which appear to be degraded merely break apart into very small pieces. These pieces are hard to see, but can still take decades or centuries to actually break down. Other products are made from materials which undergo a more rapid breakdown than non-biodegradable products. If the speed of this degradation is such that the product will degrade within a period of less than approximately 24 months under normal environmental conditions, the product is said to be biodegradable. Achievement of products made of biodegradable materials which also meet a variety of needs, such as containers for products in a damp or wet condition, has posed a significant challenge.

Reference is made to “Current status on the biodegradability of acrylic polymers: microorganisms, enzymes and metabolic pathways involved” Itzel Gaytán, Manuel Burelo & Herminia Loza-Tavera, Applied and Biotechnology, volume 105, pages 991–1006 (2021). This mini-review describes the broad acrylic polymers (AP) diversity, their properties and uses, and the factors affecting their biodegradability, underlining the importance of standardizing biodegradation quantification techniques. They also describe the enzymes and metabolic pathways that microorganisms display to attack AP chemical structure and predict some biochemical reactions that could account for quaternary carbon-containing AP biodegradation.

Presently known coating compositions suffers from numerous drawbacks. Firstly, the coating compositions in the prior art necessitate higher gsm paper substrates (>15). Secondly, these coating materials get adsorbed only on the surface and as a result these coatings offer limited functionality. Lastly, smoothness, printability, and opacity of the coated paper substrates is significantly compromised and there is no repulpability.

KR101737002 discloses coating composition that comprise acrylic polymers with various silicone copolymers for improving water resistance, oil resistance and heat sealability.

US5837383, US5989724A, CN110073056, KR101547935B1, KR102267634 and KR101752340 disclose various ecofriendly paper coating formulations intended to be applied on paper for improving water, oil and/or vapor resistance.

It was found that the coating materials of the prior art invariably include one or more of the non-biodegradable constituents that include silicone-based compounds, Styrene-butadiene (SBR), wax with minerals. Incorporation of these materials in coating for beverage kind of applications suffer from following drawbacks:

1. The gsm size of the coating in case of these materials is usually on a higher side, typically ranging from 10 to 20gsm.
2. From regulatory perspective many of the ingredients pose a serious challenge, especially in case of cups intended to be used for beverages/QSR segment.
3. Further, all these materials also pose a threat to environment since they are not biodegradable and repulpability also get compromised with these materials.
4. Still further, none of these materials reinforce the substrate material.

Therefore, there remain a dire need for a safe, plastic-free and/or biodegradable coating composition that not only ensures superior surface finish through better coverage across the surface of the substrate but also penetrates into the paper network to improve binding and also to reduce overall gsm of the coat on substrates.

Object of the invention
It is an object of the invention to provide a plastic-free and repulpable surface coatings.

It is another object of the invention to provide a coating that penetrates deeper and fiber participates in binding.

It is yet another object of the invention to provide a coating that has a significantly reduced Gsm.

It is another object of the present invention to provide a substrate coated with the coating composition of the present invention.

It is a further object of the present invention to provide a coated substrate that offers improved sealability and improved resistance to water, oil, grease and vapor.

It is a further object of the invention to provide a coating that has applications in paperboards, soap carton, paper cup, tub and lid, paper plates, paper-based packaging, FMCG products (QSR, foods, soap, anti-microbial and single use plastic replacement) for primary, secondary, and tertiary packaging.

It is also an object of the invention to provide a coating material that is cheaper than the other available alternatives.

Summary of the invention
Accordingly, the present invention provides a plastic free and biodegradable coating composition comprising:
a. 45-55% by weight at least one acrylic polymer selected from acrylic acid, butyl acrylate, methylacrylate, ethyl acrylate, butyl methacrylate, methyl methacrylate, methyl propiolate, and combinations thereof;
b. 40-50% by weight at least one media and
c. 2-5% by weight anti-block agent selected from the group consisting of methyl methacrylate monomer, butyl acrylate monomer, carbonyl diimidazole groups, zirconium carbonate groups, calcium carbonate and thereof; such that said coating provides a coat of 4 gsm to 10 gsm on a substrate.

According to another aspect of the present invention there is provided a substrate coated with the coating composition of the present invention.

Brief description of Accompanying Figures
Figure 1 illustrates the substrate and coating deposition
Figure 2 illustrates the particle size optimization for effective barrier
Figure 3 illustrates the Rheology of formulation at constant shear & temperature.
Figure 4 illustrates the CLSM Imaging of the Uncoated and Coated Indobase – 165 GSM Boards
Figure 5 illustrates the air permeability of the coated and uncoated substrate
Figure 6 illustrates the comparison between COBB, Seal Strength and Coat wait (Indobase – 165 GSM)
Figure 7 illustrates the process of formulation and coating in accordance with the present invention.

Description of the invention
The terms and words used in the following description and claims are not limited to the bibliographical meanings, but, are merely used by the inventor to enable a clear and consistent understanding of the present disclosure. Accordingly, it should be apparent to those skilled in the art that the following description of various embodiments of the present disclosure is provided for illustration purpose only and not for the purpose of limiting the present disclosure as defined by the appended claims and their equivalents.

The terminology used herein is for the purpose of describing particular various embodiments only and is not intended to be limiting of various embodiments. As used herein, the singular forms "a," "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "comprises" and/or "comprising" used herein specify the presence of stated features, integers, steps, operations, members, components, and/or groups thereof, but do not preclude the presence or addition of one or more other features, integers, steps, operations, members, components, and/or groups thereof. Also, Expressions such as "at least one of," when preceding a list of elements, modify the entire list of elements and do not modify the individual elements of the list.

In the context of the present invention, Acrylic Polymers (AP) means at least one or more of the polymers that includes but is not limited to Acrylic acid, Butyl Acrylate methylacrylate, Ethyl acrylate, Butyl methacrylate, Methyl methacrylate, Methyl propiolate, and combinations thereof.

The expression “substrate” means paper, paperboard, cup or containers or any other packaging units made therefrom.

The expression “Plastic” means material which contains as an essential ingredient a high polymer such as polyethylene terephthalate, high density polyethylene, Vinyl, low density polyethylene, polypropylene, polystyrene resins, multi-materials like acrylonitrile butadiene styrene, polyphenylene oxide, polycarbonate and Polybutylene terephthalate.

The expression, “Anti-block agent” in the context of the present invention means compounds that include but are not limited to avoid the blocking issues during the conversion process.

The present invention provides a plastic-free, repulpable coating composition that improves sealability, water resistance, and oil and grease resistance of the substrate. Further, apart from the coating on the surface, the coating composition also penetrates deeper in the substrate thereby improving the overall binding. The coat thickness (5 gsm – 10gsm) obtained using the coating composition of the present invention is substantially lower than its prior art counter parts (more than 15 gsm onwards). The plastic-free, repulpable coating composition of the present invention comprises at least one acrylic polymers, at least one media; and an anti-block agent.
In one aspect, the present invention provides a plastic free and/or biodegradable coating composition comprising:
a. at least one acrylic polymers;
b. at least one media; and
c. anti-block agent

Optionally, the coating composition further comprises an emulsifying agent and a leveling agent.

A typical composition of the plastic free and/or biodegradable coating composition of the present invention is shown in Table 1 below.
Table 1
S.No Ingredients Wt.% concentration range
1 Methyl Acrylate (AP)

45-55%
2 Ethyl Acrylic (AP)
3 Acrylate Acrylic (AP)
4 Butyl Acrylic (AP)
5 Water 40-50%
6 Anti-block 2-5%

Typically, the amount of AP varies from 45 wt% to 55 wt% while the amount of media ranges from 40 wt% to 50 wt%. Typically, AP is selected from a group that includes but is not limited to Acrylic Acid, Butyl Acrylate methylacrylate, Ethyl acrylate, Butyl methacrylate, Methyl methacrylate, Methyl propiolate, and combinations thereof.

It is known that AP is not completely soluble in water. In some of the embodiments, AP as employed in the coating composition of the present invention is in the form of a readily available emulsion form.

In some of the preferred embodiments, the media used for the manufacture of plastic free and or biodegradable coating composition of the present invention is water.

It was observed that polymer to water ratio in the present coating formulation is 1:1.25 to 1:1.4. Change in this ratio of polymer to water affects the properties of coated substrate.

Typically, the emulsifying agent is selected from the group that includes but is not limited to alkyl sulfate, alkyl lauryl ether sulfate. The emulsifying agent is present in an amount 3 to 5 % by weight.

Typically, the anti-block agent is at least one selected from the group consisting of methyl methacrylate monomer, butyl acrylate monomer, carbonyl diimidazole groups, zirconium carbonate groups, calcium carbonate and etc.

In another aspect of the present invention, there is provided a substrate coated with the coating composition of the present invention. In some of the embodiments, the substrate is a cupstock type of substrate. In other embodiments, the substrate is adapted for QSR segment. Depending upon the end use case, the gsm (gram per square meter) of the substrate keeps varying. The gsm of the cup stock type substrate typically varies between 130 gsm to 350 gsm more preferably, between 150 gsm to 300 gsm. The gsm of the substrate adapted for QSR segment varies between 130 to 400 gsm, more preferably between 150 gsm to 350 gsm. In some embodiments, the substrate is multilayered while in some embodiments, the substrate may be single layered. In some of the exemplified embodiments, the substrate comprises at least one pulp layer sandwiched between one or more layers of surface sizing agents. The pulp layer within the substrate may be bleached or it may be chemical based non-bleached layer.

Without bound by theory, it is believed that the coating composition of the present invention penetrates into fibrous network of the substrate and not only improves binding but also imparts strength. Further, this also substantially reduces the coating requirement (gsm). Typically, the deposited coat on the substrate varies from 4 gsm to 10 gsm.

The particle size of the coating formulation for the desired coat is <100nm

The coated substrate according to the present invention typically is characterized by at least one of the following parameters:

3M Kit Value (Oil & Grease Resistance): Greater than 6, preferably greater than 10;
COBB (3 min): below 2, preferably below 1;
Sealability (g/25mm or Fiber Tear) : Greater than 270, preferably more than 300;
Cup Conversion (Cups/Min In current m/c) in a range that varies between 35 to 70
In yet another aspect of the invention, there is provided a process to manufacture the coating composition of the present invention. The process includes mixing the at least one Acrylic Polymers into the mixer (a vertical homogenizer) along with anti-block, defoamer at room temperature for about 1 – 3 hours to obtain plastic free and/or biodegradable coating composition. Defoamers can be silicone and water-based deformers.

In a further aspect of the present invention, there is provided a method for applying the coating composition onto the preselected substrates to attain coat with desired GSM and desired sealability characteristics.

The present plastic-free and or biodegradable packaging solution is an alternative to PE Extrusion, PLA extrusion, among others. It has applications in paperboards, soap carton, paper cup, tub and lid, paper plates, and paper-based packaging. It is also cheaper than the other available alternatives. The coating composition of the present invention can be used for FMCG Products (QSR, foods, soap, anti-microbial and single use plastic replacement) for primary, secondary, and tertiary packaging.

The present invention is now illustrated by way of non-limiting working examples.

Working example 1: Coating Composition
Table 2
S.No. Ingredients Wt%
1 Butyl Acrylic (AP) 45%
2. Water 50%
3 Sodium Lauryl Ether Sulphate 2%
4 Antiblock (Methyl methacrylate monomer) 3%

The method of preparing a coating composition comprises:
i. selecting at least one acrylic polymer;
ii. dissolving the acrylic polymer in water to obtain a slurry,
iii. adding at one excipient selected from the group consisting of surfactant, antiblock agents to obtain a coating composition. (amounts taken in accordance with Table 2)

The coating composition in accordance with the present invention is typically characterized by viscosity ranging from 25 to 35 seconds in B4 cups while the pH range from 6.5 to 7.5.

Total Solids in the coating composition varies from 40 to 55.

The plastic-free and or biodegradable coating composition of the present invention is non-plastic, repulpable and biodegradable and provide high barrier properties to various types of paper and paper board substrates.

Working Example 2: Coated Substrates: Test Data
A cupstock type of substrates namely Indobase – 165, Indobase – 170, Indobase - 175 were selected for coating. The coating composition as prepared in Example 1 was used to coat these substrates. Figure 1 illustrates the substrate and coating deposition.

The process includes mixing the at least one Acrylic Polymers into the mixer (a vertical homogenizer) along with anti-block, defoamer at room temperature for about 1 – 3 hours to obtain plastic free and/or biodegradable coating composition. Defoamers can be silicone and water-based deformers.

The method for applying the coating composition onto the preselected substrates to attain coat with desired GSM and desired sealability characteristics is done by using coating rod for single layer application. The coated substrate was then dried in a hot air oven at 120°C for 10 mins. Further, the dried sample was allowed to condition at 27°C and 65% RH for 24hrs before testing for desired properties.

The coating formulation when applied on the substrate forms a uniform layer on the top of the substrate, which penetrates into the pores of the Paper/ Paper board. Thus, on drying, the coated substrate will have some of the coated formulation within it blocking the pores and some on the top and as a barrier layer (Figure 1).

Provided below is the test data for each of these coated substrates using the standard methods as provided below:

Coat Weight measurement: Standard: TAPPI T410
Cobb measurement: Standard: TAPPI T441
Heat Sealability measurement: Standard: ASTM F2029
Oil and Grease resistance measurement: Standard: TAPPI T559
The coating allowed excellent hydrophobicity, heat sealability and was found to be repulpable as shown in Table 3.
Table 3
Paper board
& GSM Number of Pass OGR
(3MKIT) Coat weight
(g/m2) Cobb - 3 min
(g/m2) Sealability
(165 °C/1 sec)
Indobase - 165 2 14 Pass 5-7 < 1 Good, Fiber Tear
Indobase - 170 2 14 Pass 5-7 < 1 Good, Fiber Tear
Indobase - 175 2 14 Pass 5-7 < 1 Good, Fiber Tear

Surface Characteristics:
The coated and uncoated cup stock type of substrate was evaluated for its surface characteristics using CLSM imaging. No pinhole was observed in the coated substrate thereby indicating the penetration of the coating inside the coated substrate as shown in Figure 4.

In CLSM (Confocal Laser Scanning Microscopy) measurement, many pinholes and uncoated surface image in blank sample were observed whereas in the coated samples, full film formation without pinhole in the sample was observed.

Air Permeability Measurement: Uncoated & Coated Indobase – 165 GSM Board (Figure 5)
Table 4
Air Permeability (ml/min/cm2)
Sl.no Uncoated paper
(166 gsm) Coated Paper
(173gsm)
1 14.7 0.2
2 15.1 0.8
3 16.1 0.6
4 14.7 0.2
5 13.7 0.4
6 15.8 0.8
7 15.1 0.2
8 14.8 0.4
9 14.3 0.3
10 13.8 0.2
Average 14.81 0.46
Remarks: NA 96.89% Closed

Inference
The graph in Figure 6 explains that at the coat weight of ~ 6-7 gsm, the cobb was achieved below 1 with the good seal strength of 0.5 Kg/25 mm. The lower coat weight is impacting cobb (higher) as well as lower seal strength. However, beyond the optimum coat weight, there was no significant improvement.

This shows that surface coatings only act as a layer on surface. While the composition of the present invention penetrates deeper and fiber participates in binding. Gsm requirements, thus, is significantly reduced. In addition, novel properties such as plastic-free and repulpable add value and widens the scope of coating for liquid segment.

Example 3
Table 5 shows the comparative data showing the criticality of the respective weights of the components of the present composition.
Table 5
S.No. Ingredients Wt% Wt% Wt% Wt% Wt% Wt% Wt%
Exp-1 Exp-2 Exp-3 Exp-4 Exp-5 Exp-6 Exp-10
1 Butyl Acrylic (AP) 35 40 45 55 45 45 60
2 Water 60 55 50 40 53 52 35
3 Sodium Lauryl Ether Sulphate 2 2 2 2 2 0 2
4 Antiblock (Methyl methacrylate monomer) 3 3 3 3 0 3 3
5 Remark Not Working Working Not Working Not Working

The present inventors have found that emulsifying agent is very critical in stabilizing the emulsion formed during the formation of acrylate in the medium. The amount of emulsifying agent is chosen on the basis of the concentration of acrylate in formulation. Sodium lauryl ether sulphate is taken in the right amount required to stabilize the acrylates. At higher concentration, since the formulation is water based, will result in foaming during mixing and coating and increase in water absorption of board, which in turns results in bubbles on the coating substrate thus non-uniformity in coating.

Table 6
S.No. Ingredients Wt% Wt% Wt%
Exp-7 Exp-8 Exp-9
1 Butyl Acrylic (AP) 35% 40% 40%
2 Water 62% 57.5% 52%
3 Sodium Lauryl Ether Sulphate 2% 2% 2%
4 Antiblock (Methyl methacrylate monomer) 1% 0.5% 6%
5 Remark Not Working

From the data above in Table 6 it can be observed that anti-blocking agent at ranges less than 2 results in improper curing and blocking of the sheets when wound in the reel form. When anti-blocking agent ranges greater than 5, it affects the sealability.
The compositions of Exp-1, Exp-2 and Exp-5 & Exp-6 did not achieve the expected results as they had higher cobb (>3 gsm) and high stickiness/blocking was observed heavily during downstream process/conversion process. The final product had high sogginess if the resulting Cobb (in 3 min) is more than 3 gsm.

Table 7 shows the various properties of the coating compositions of Tables 5 and 6
Table 7

Paper board
& GSM Number of Pass OGR
(3MKIT) Coat weight
(g/m2) Cobb - 3 min
(g/m2) Sealability
(165 °C/1 sec) Remarks
Expt 1 2 4 Pass 4-5 12 No sealing Poor barrier property
Expt 2 2 8 Pass 5-7 6 Sealing without fibre tear Poor barrier property
Expt 3 2 14 Pass 5-7 <1 Good, Fiber Tear -
Expt 4 2 14 Pass 5-7 <1 Good, Fiber Tear -
Expt 5 2 14Pass 5-7 <1 Good, Fiber Tear Sticking observed in Paper reel
Expt 6 - - - - - Emulsion not stable
Expt 7 2 4 Pass 4-5 12 No Sealing Poor barrier property
Expt 8 2 8 Pass 5-7 6 Sealing without fibre tear Sticking observed in Paper reel
Expt 9 2 8 Pass 5-7 6 No sealing Poor barrier property
Expt 10 2 14 Pass 10-12 <2 Good, Fiber Tear High Viscosity

Table 7 illustrates how change in polymer to water ratio effects the barrier properties of coated substrates and the role of Emulsifier in stabilizing the formulation. Anti-blocking agent at higher concentration resulted in poor sealing without affecting barrier properties. At lower dosage it was not affective in performing as Anti-blocking agent. At higher concentration of Acrylic polymer and lower concentration of water, as mentioned in Expt 10, viscosity of the formulation increases and is not suitable for coating machine. Higher GSM was deposited on substrate with similar property as was obtained at lower GSM with of AP at 45-55%.

It was observed that polymer to water ratio for working example is 1:1.25 to 1:1.4. Change in this ratio of polymer to water affects the properties of coated board.

Example 4
Synthesis and coating process:
Figure 7 details the flow chart on the synthesis of the present coating formulation and process of coating. Acrylic polymer with monomer as initiator was dispersed in a medium of water. Formulation optimization done with varying ratio of the AP, emulsifier and Anti-blocking agent in accordance with the present invention. The formulation was thus coated on the substrate which post drying close pores and forms film thus giving the barrier.

Example 5
Experiments were conducted with polymers other than Acrylic Acid, Butyl Acrylate methylacrylate, Ethyl acrylate, Butyl methacrylate, Methyl methacrylate, Methyl propionate to demonstrate the criticality in the selection of the polymers.
It was observed that other polymers like, Poly (2-hydroxyethyl methacrylate), poly(2-ethylhexyl acrylate), Polyacrylamide were hygroscopic and have potential to retain moisture. Hence could not be used in the present invention.

Below is the data for one representative example with coating formulation prepared with Poly (2-hydroxyethyl methacrylate):

Table 8
S.No. Ingredients Wt%
1 Poly(2-hydroxyethyl methacrylate) 50%
2 Water 45%
3 Sodium Lauryl Ether Sulphate 2%
4 Antiblock
(Methyl methacrylate monomer) 3%
Remark Not working

Formulation turned viscous and was not suitable for coating.

Example 6
A study on the variation of the particle size of the coating composition affecting hydrophobicity and viscosity was performed with the composition in Table 9.

Table 9
S.No. Ingredients Wt%
1 Butyl Acrylic (AP) 45%
2. Water 50%
3 Sodium Lauryl Ether Sulphate 2%
4 Antiblock (Methyl methacrylate monomer) 3%

Fig 2 and table 10 below depicts the increase in hydrophobicity in other terms increase in contact angle of the coated substrate with decrease in particle size of the formulation. As observed from Table 10, particle size reduction was observed in terms of emulsion through homogenization. High speed mechanical stirring helps breakdown the emulsion aggregates thus resulting in uniform dispersion and better barrier. This was validated with the Particle size analysis instrument through DLS method.

At particle size <100nm in formulation, maximum contact angle was obtained for the coated substrate. It was observed that at homogenization beyond 1 hour did not result in any further reduction in size of emulsion.
Table 10
Mean particle Size COBB (gsm) Contact Angle (0) Hours of homogenization
1020 nm 5 - 6 50 – 60 0
220 nm < 3 70 – 75 0.5
80 nm < 1 105 – 110 1
76nm <1 105 - 110 2

From Fig 3, it was observed that with the decreasing particle size, viscosity of the formulation also decreased. Viscosity reduced from 2600cP for 1000nm to 900cP for 80nm particle size.
It is found that the particle size range for the desired coat is <100nm.
,CLAIMS:
1. A plastic free and biodegradable coating composition comprising:
a. 45-55% by weight at least one acrylic polymer selected from acrylic acid, butyl acrylate methylacrylate, ethyl acrylate, butyl methacrylate, methyl methacrylate, methyl propiolate, and combinations thereof;
b. 40-50% by weight at least one media and
c. 2-5% by weight anti-block agent selected from the group consisting of methyl methacrylate monomer, butyl acrylate monomer, carbonyl diimidazole groups, zirconium carbonate groups, calcium carbonate and thereof; such that said coating provides a coat of 4 gsm to 10 gsm on a substrate.

2. The plastic free and biodegradable coating composition as claimed in claim 1, wherein said coating provides a sealability of greater than 270 g/25mm, preferably more than 300 g/25mm.

3. The plastic free and biodegradable coating composition as claimed in claim 1, wherein said media is water.

4. The plastic free and biodegradable coating composition as claimed in claim 3, wherein said polymer to water ratio in the present coating formulation is 1:1.25 to 1:1.4.

5. The plastic free and biodegradable coating composition as claimed in claim 1, wherein said composition further comprises emulsifying agent.

6. The plastic free and biodegradable coating composition as claimed in claim 5, wherein said emulsifying agent is selected from alkyl sulfate, alkyl lauryl ether sulfate.

7. The plastic free and biodegradable coating composition as claimed in claim 5, wherein said emulsifying agent is present in an amount 3 to 5 % by weight.

8. The plastic free and biodegradable coating composition as claimed in claim 1, wherein said substrate is made into one selected from paperboards, soap carton, paper cup, tub and lid, paper plates, and paper-based packaging.

9. The plastic free and biodegradable coating composition as claimed in claim 1, wherein said coating composition is used for FMCG Products such as QSR, foods, soap, anti-microbial and single use plastic replacement for primary, secondary, and tertiary packaging.

10. A substrate coated with the coating composition as claimed in any of claims 1 to 9.