Packaging material having moisture barrier and methods for preparing same

A method comprising the following steps:

• (a) providing a calendered printable material comprising:
• a paper substrate comprising at least about 40% recyclable paper fibers and having an inner surface and an outer surface;
• and
• a print-receptive layer having an inner surface and a calendered outer surface positioned over the paper substrate outer surface, wherein the print-receptive layer inner surface is positioned over the paper substrate outer surface and wherein the calendered print-receptive layer outer surface has a Parker Print Smoothness value of about 1.5 or less;
• (b) applying an energy-curable coating comprising one or more energy-curable monomers over the calendered print-receptive layer outer surface;
• and
• (c) curing the energy-curable monomers to form a moisture barrier layer comprising one or more recyclable energy-cured polymers positioned over the calendered print-receptive layer outer surface to provide a recyclable printed packaging material having a water vapor transportation rate of about 500 g/m2/day or less.

A method comprising the following steps:

• (a) providing an unreeled printable material comprising:
• a paper substrate having an outer surface and inner surface;
• and
• a print-receptive layer having an inner surface and an outer surface, wherein the print-receptive layer inner surface is positioned over the paper substrate outer surface and wherein the print-receptive layer outer surface has a Parker Print Smoothness value of about 1.5 or less;
• (b) depositing print colorant on the print-receptive layer outer surface to form one or more printed areas to provide a printed material;
• (c) applying to the printed material an energy-curable coating comprising one or more energy-curable monomers over the print-receptive layer outer surface, including the printed areas, to provide a coated printed material;
• and
• (d) curing the energy-curable monomers to form a moisture barrier layer comprising one or more energy-cured polymers positioned over the coated print-receptive layer outer surface to provide a printed packaging material having a water vapor transportation rate of about 500 g/m2/day or less;
• wherein steps (a) through (d) are carried out as a single pass operation and without reeling up:
• the printed material of step (b) prior to carrying step (c);
• and the coated material of step (c) prior to carrying out step (d).