Method of producing a multilayer coated substrate having improved barrier properties

A method of producing a coated basepaper or paperboard substrate comprising the steps of:

• a) forming a composite, multilayer free flowing curtain, wherein at least one of the layers of the curtain has a coatweight when dried of less than about 30 g/m2, the curtain has a solids content of at least about 40 wt. %, and wherein the curtain has an interface layer, and the interface layer of the curtain has a viscosity of at least about 430 centipoise, whereby the multilayer free flowing curtain comprises at least two layers imparting at least two different barrier functionalities selected from the group consisting of oil and/or grease barrier functionality, water vapor barrier functionality, water resistance functionality, and oxygen barrier functionality, and wherein the free flowing curtain comprises an additional top layer providing printability;
• b) contacting the curtain with a continuous basepaper or paperboard web substrate having a velocity of at least about 200 m/min., whereby, in case an oil and/or grease barrier layer is present in the multilayer curtain the coated substrate has a Kit value of at least about 5 in the flat-test, in case a water vapor barrier layer is present in the multilayer curtain the coated substrate has a water vapor transmission rate of less than about 50 g/(m2/day) (50% relative humidity, 23° C.),
• in case a water resistance layer is present in the multilayer curtain the coated substrate has a 10 minute Cobb value of less than about 20 g/m2,
• in case an oxygen barrier layer is present in the multilayer curtain the coated substrate has an oxygen transmission rate of less than about 200 cm3/(m2d/bar) (1 atm, 23° C., 90% relative humidity).