Barrier recycled paperboard and method for manufacturing thereof

A method for manufacturing coated paperboard, the method comprising:

• applying a first layer of aqueous barrier coating over a first side of a recycled paperboard substrate, wherein the first layer of aqueous barrier coating comprises a first mixture of binder and pigment, wherein the binder of the first layer of aqueous barrier coating is present in the first mixture in an amount of 30 to 50 parts per 100 parts of pigment by weight, wherein the recycled paperboard substrate is produced from at least 50%, by weight, recovered fibers;
• and
• applying a layer of second aqueous barrier coating over the first layer of aqueous barrier coating, wherein the second layer of aqueous barrier coating comprises a second mixture of binder and pigment, wherein the binder of the second layer of aqueous barrier coating is present in the second mixture in an amount of 30 to 50 parts per 100 parts of pigment by weight,
• wherein the coated paperboard has a 3M kit test value of at least 5, a 30-minute oil Cobb test of at most 5 grams per square meter, a 2-minute water Cobb of less than 60 grams per square meter, a water vapor transmission rate of less than 800 grams per square meter per day, and is repulpable to the extent that after repulping the percentage accepts is at least 85%.

A coated paperboard comprising:

• a recycled paperboard substrate having a first side and a second side, wherein the recycled paperboard substrate is produced from at least 50%, by weight, recovered fibers;
• a first layer of aqueous barrier coating applied over the first side, wherein the first layer of aqueous barrier coating comprises a first mixture of binder and pigment, wherein the binder of the first layer of aqueous barrier coating is present in the first mixture in an amount of 30 to 50 parts per 100 parts of pigment by weight, wherein the first layer of aqueous barrier coating includes an additive, wherein the additive is a viscosity modifier;
• and
• a second layer of aqueous barrier coating applied over the first layer of aqueous barrier coating, wherein the second layer of aqueous barrier coating comprises a second mixture of binder and pigment, wherein the binder of the second layer of aqueous barrier coating is present in the second mixture in an amount of 30 to 50 parts per 100 parts of pigment by weight,
• wherein the coated paperboard has a 3M kit test value of at least 5, a 30-minute oil Cobb test of at most 5 grams per square meter, a 2-minute water Cobb of less than 60 grams per square meter, a water vapor transmission rate of less than 800 grams per square meter per day, and is repulpable to the extent that after repulping the percentage accepts is at least 85%.

A method for manufacturing coated paperboard, the method comprising:

• applying a first layer of aqueous barrier coating over a first side of a recycled paperboard substrate, wherein the recycled paperboard substrate is produced from at least 50%, by weight, recovered fibers, wherein the first layer of aqueous barrier coating comprises a first mixture of binder and pigment, wherein the binder of the first layer of aqueous barrier coating is present in the first mixture in an amount of 30 to 50 parts per 100 parts of pigment by weight, and wherein the first layer of aqueous barrier coating includes an additive, wherein the additive is a viscosity modifier;
• and
• applying a second layer of aqueous barrier coating over the first layer of aqueous barrier coating, wherein the second layer of aqueous barrier coating comprises a second mixture of binder and pigment, wherein the binder of the second layer of aqueous barrier coating is present in the second mixture in an amount of 30 to 50 parts per 100 parts of pigment by weight,
• wherein the coated paperboard has a 3M kit test value of at least 5, a 30-minute oil Cobb test of at most 5 grams per square meter, a 2-minute water Cobb of less than 60 grams per square meter, a water vapor transmission rate of less than 800 grams per square meter per day, and is repulpable to the extent that after repulping the percentage accepts is at least 85%.