Design and Statistical Optimization of <scp>PLA</scp> Organoclay‐Based Dispersions for Recyclable Packaging Paper

ABSTRACT Performance and recyclability of paper coatings depend on precise control of polymer, surfactant, filler compositions as well as oil to water ratios to produce stable dispersions and defect‐free films. These factors determine fiber polymer interactions and coating removability during repulping, which are critical for efficient fiber recovery and recyclable packaging. This study examines PLA organoclay aqueous dispersions stabilized by sodium dodecyl sulfate (SDS), emphasizing particle size, zeta potential, and solids content. Using a full factorial design (2 4 ) and stepwise regression, predictive equations have been established to identify the dominant formulation factors and illustrate their combined effects through response surface modeling. The most promising formulation within the tested range (PLA 10.65 wt%, SDS 0.10 wt%, organoclay 3 wt%, oil‐to‐water ratio 1.4) was selected from the JMP Profiler using a multi‐criteria optimization, simultaneously maximizing solids content while maintaining submicronic particle size. This formulation yielded ~13% solids, kinetically stable dispersions, and defect‐free coatings. Under laboratory‐scale settings, repulpability tests revealed effective disintegration (94.7% ± 1.5% fiber recovery) without foaming. Overall, this study proposes a formulation‐driven optimization technique for producing recyclable, bio‐based PLA‐organoclay coatings for recyclable paper packaging, guided by a design of experiments strategy.