Date of Defense

4-21-2026

Date of Graduation

5-2026

Department

Chemical and Paper Engineering

First Advisor

Mert Atilhan

Second Advisor

James Springstead

Abstract

The objective of this project is to develop a grease-resistant barrier coating for paper-based food packaging and to evaluate the economic feasibility of implementing this coating system at an industrial scale. As demand increases, this project focuses on identifying an optimal pigment and binder combination that enhances barrier performance while maintaining cost-effectiveness. The primary goal was to maximize grease and moisture resistance of coated paper while ensuring the process is economically viable and compatible with existing paper mill operations.

The final plant design consists of one continuous stirred tank reactor (CSTR) and three centrifugal pumps integrated into an existing paper production line where the system mixes pigment and binder streams before application to paper. The reactor operates at 35°C and 1 atm with a total volume of 2.504 m³. The selected optimal formulation is Trinseo Ligos B7301 binder combined with Hydrocarb 60 pigment, based on laboratory testing including hot oil, Cobb, and fold-crack tests. These tests demonstrated strong grease resistance, water resistance, and mechanical durability compared to other tested formulations.

The CSTR and piping is constructed of stainless steel to ensure durability and compatibility with water-based coating materials. The system requires some heating, with a total heating duty of approximately 149.23 kW and minimal electrical demand for pumping. Utility costs are relatively low, totaling approximately $4.54 per hour. The total equipment cost for the reactor and pumps is $18,019.98, which results in a Fixed Capital Investment (FCI) of $541,848 and a Total Capital Investment (TCI) of $637,468.

At full-scale operation, the plant produces approximately 73,160 m³ of coating annually, generating $14.63 million in revenue based on a selling price of $2,000 per ton. Raw material costs, dominated by binder usage, total approximately $34.99 million annually. Including labor, utilities, maintenance, and overhead, total annual operating expenses are $7.45 million, resulting in a net annual profit of approximately $7.11 million before depreciation.

An economic analysis was conducted assuming a 10-year plant life, 10% minimum acceptable rate of return (MARR), federal and state taxes, and 7-year MACRS depreciation. The Return on Investment (ROI) was calculated to be 1,118%, with a payback period of 0.10 years. The Net Present Value (NPV) is $7.13 million, and the Internal Rate of Return (IRR) is 826%, significantly exceeding the MARR. The Equivalent Uniform Annual Worth (EUAW) is $5.26 million per year.

Sensitivity analysis was performed by varying income by ±30%. When increased by 30%, the NPV rises to $11.5 million with significantly higher returns. When decreased by 30%, the NPV becomes negative, indicating that profitability is highly sensitive to market pricing of coated paper products.

Overall, the technical and economic results demonstrate that the proposed coating system is both feasible and highly profitable. Based on these findings, it is recommended that implementation of the Trinseo Ligos B7301 and Hydrocarb 60 coating system be pursued at an industrial scale.

Comments

Co-authored with:

Ashley David

Sydney Moranko

Abbygayle Ruggierio

Access Setting

Honors Thesis-Open Access

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