New graphene oxide coating could enable PFAS-free food packaging

The patent-pending material offers enhanced barrier properties and significantly increases the strength of paper-based packaging.

Researchers at Northwestern University have developed a graphene oxide coating that provides water- and oil-resistance, potentially enabling PFAS-free food packaging as a safer alternative to harmful plastics and toxic chemicals.

The patent-pending material, which is being commercialised by GO-Eco, a startup based at Northwestern’s Querrey InQbation Lab and a subsidiary of Chang Robotics, offers enhanced barrier properties and significantly increases the strength of paper-based packaging. Unlike conventional coatings, the product is non-toxic, affordable and environmentally friendly.

“This is not just a materials innovation; it’s a market-ready solution,” said Timothy Wei, co-developer of the coating and chief scientist at Chang Robotics. “We are thrilled to be taking GO-Eco from the lab to the factory floor, with applications that could ultimately transform the entire food packaging industry.”

The new coating addresses increasing regulatory pressure to phase out PFAS (per- and polyfluoroalkyl substances), chemicals widely used for their water- and oil-resistant properties but associated with environmental persistence and health risks.

As of 2024, 13 US states have enacted laws restricting PFAS in food containers and packaging materials, driving demand for PFAS-free food packaging alternatives.

According to GO-Eco’s analysis, the US produces approximately 14 million metric tonnes of paper-based food packaging and corrugated cardboard annually, generating over $60 billion in sales. Most of these products currently rely on plastic or PFAS coatings for protection, despite mounting regulatory and consumer concerns.

Coating development and testing

The graphene oxide coating was developed by Wei, adjunct professor at Northwestern’s McCormick School of Engineering, and SonBinh Nguyen, professor of chemistry at Northwestern’s Weinberg College of Arts and Sciences. The pair combined expertise in advanced manufacturing and graphene oxide science to create a proprietary process that enhances the barrier and mechanical properties of paper and cardboard packaging.

Tests on various prototypes, including disposable plates, cups, straws, cardboard boxes and plastic produce bags, demonstrated resistance to water, oil and grease, while boosting paper strength by 30 to 50 per cent compared with existing commercial coatings.

The product has undergone independent, industry-standard testing at Western Michigan University’s Paper Pilot Plant. These evaluations confirmed the coating’s effectiveness across different materials, including moulded fibre tableware and corrugated cardboard, while maintaining costs comparable to current barrier solutions.

GO-Eco, with backing from Northwestern’s Office of Undergraduate Research and a major national tableware manufacturer, is now looking to scale production and pursue FDA approval for food-contact use. The company also plans to certify the material for recyclability and compostability, and will conduct full-scale production trials on moulded fibre and conventional paper-sheet packaging to support wider adoption of PFAS-free food packaging.