Cellulose
and chitin are the two most abundant naturally
produced
biopolymers and are being extensively studied as candidates for renewable
oxygen barrier films used in packaging. It has been shown that bilayers
formed from cellulose nanocrystals (CNCs) and chitin nanofibers (ChNFs)
exhibit oxygen barrier properties similar to polyethylene terephthalate
(PET). However, this prior work explored only coating each layer individually
in sequence through techniques such as spray coating. Here, we demonstrate
the viability of dual-layer slot die coating of CNC/ChNF bilayers
onto cellulose acetate (CA) substrates. The dual-layer slot die method
enables significantly lower oxygen permeability versus spray coating
while using a roll-to-roll system that applies the bilayer in a single
pass. This work discusses suspension properties, wetting, and drying
conditions required to achieve well-controlled ChNF/CNC bilayers.
Spray-coated bilayer films were on average 25% thinner than the dual-layer
bilayer film; however, the thickness-normalized oxygen permeability
(OP) of the dual-layer-coated ChNF/CNC bilayer film on CA was 20 times
better than that of the spray-coated bilayers. It has been shown that
ChNF contributes to the wetting and barrier properties. Values of
OP for the slot die-coated bilayers under optimized drying conditions
were as low as 1.2 cm3·μm·m–2·d–1·kPa−1, corresponding
to a normalized oxygen transmission rate of 0.32 cm3·m–2·d–1 at 23 °C and 50%
relative humidity. It is also noted that the adhesive properties of
the dual-layer coating are also improved when films are air-dried
and that ChNF contributes to the wetting and barrier properties.