The world is drowning in single-use-plastic waste. Compostable and recyclable alternatives to single-use flexible packaging exist but do not provide an adequate barrier to water-vapor and oxygen. We address this by using atmospheric-pressure spatial atomic layer deposition to apply Al2O3-ZnO nanolaminates on compostable polylactic acid (PLA) and recyclable polyethylene terephthalate (PET) films for flexible packaging. This industrially scalable coating is performed at 50 °C, preserving film integrity while enabling nanoscale control. The nanolaminate structure is found to enhance the bending resistance, improve the coating stability, and drastically reduce the water-vapor transmission rate (WVTR) and oxygen transmission rate (OTR). An optimized 8-stack Al2O3-ZnO nanolaminate that is ∼96 nm thick reduces the WVTR of PLA packaging film from ∼300 g m−2·24hr−1 to <0.5 g m−2·24hr−1 and its OTR from ∼1000 cm3 m−2·24hr−1 to <10 cm3 m−2·24hr−1 (both measured at 38oC and 90 % relative humidity), making it ideal for packaging air-sensitive goods. When the 8-stack nanolaminate is laminated between two PET films to form a simple packaging structure and is subjected to the harshest industry-standard Gelbo flex durability testing, it retains a WVTR <2 g m−2·24hr−1. These ultrathin coatings are well-positioned to meet recyclability and compostability standards, enabling a viable path to sustainable flex packaging.
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