The new PEG-ZnO coating enhances face masks and gowns with lab-proven nanotech that resists pathogens without compromising breathability or clarity.
Study: Advanced antimicrobial coatings for PPE: synergistic effects of polyethylene glycol and ZnO nanoparticles. Image Credit: PhotobyTawat/Shutterstock.com
Researchers have developed a high-performance antimicrobial coating for personal protective equipment (PPE) by combining polyethylene glycol (PEG) with zinc oxide (ZnO) nanoparticles.
Published in the Journal of Coatings Technology and Research, the study highlights how this composite coating improves microbial resistance on PPE fabrics. This improvement could have direct implications for healthcare infection control.
The PEG-ZnO coating significantly reduced viral and bacterial loads on lab coat and mask fabrics, with the 0.75 wt% ZnO formulation showing the highest overall efficacy.
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Nosocomial Infections as a Persistent Threat in Healthcare
Hospital-acquired infections remain a major health and economic burden, affecting vulnerable patients and healthcare workers alike. Although PPE is essential for infection control, traditional fabrics can harbor pathogens and even support their spread, rather than limit them.
In response, researchers are exploring surface coatings with built-in antimicrobial functions. ZnO nanoparticles, known for broad-spectrum antibacterial and antiviral activity, offer a promising solution.
Polyethylene glycol (PEG) complements these properties with its high wettability, improving nanoparticle dispersion and surface interactions. PEG’s hydrophilic nature also enhances surface coverage, ensuring better exposure of ZnO particles to microbial contaminants.
Designing and Testing PEG/ZnO Coatings
The research team formulated PEG/ZnO composite coatings using an acrylic-PEG resin base and ZnO nanoparticles in varying concentrations: 0.2 %, 0.5 %, 0.75 %, and 1.0 wt%.
The coatings were spray-applied to clean substrates, including glass slides, lab coat fabric, and face mask fabric, and dried at room temperature.
To evaluate the coatings, the study employed a suite of material characterization methods. Scanning electron microscopy (SEM) and atomic force microscopy (AFM) were used to observe surface morphology, while energy-dispersive X-ray spectroscopy (EDX) confirmed elemental composition.
Chemical bonding interactions were assessed using Fourier-transform infrared spectroscopy (FTIR), and ultraviolet-visible (UV-Vis) spectroscopy was used to measure the optical transparency of the coatings. Contact angle tests evaluated surface wettability, and thermogravimetric analysis (TGA) assessed thermal stability.
Biological activity was assessed using the disk diffusion method to measure antibacterial performance against Staphylococcus aureus and Escherichia coli, and antiviral efficacy was tested using a TCID50 assay with feline coronavirus as the model virus.
Best Results at 0.75 wt% ZnO
The 0.75 wt% ZnO coating demonstrated the strongest antimicrobial effects.
This wt% of ZnO nanoparticles produced inhibition zones of 30.3 ± 0.6 mm against S. aureus and 29.3 ± 0.6 mm against E. coli, along with a 99.9968 % reduction in coronavirus viral load.
While the 1.0 wt% ZnO formulation showed comparable results, the study observed diminishing returns when the coating concentration was increased beyond 0.75 wt%, indicating a saturation point in antimicrobial performance.
In addition, the 0.5 wt% concentration displayed slightly lower antiviral activity (99.99 %), a result likely linked to nanoparticle agglomeration that may reduce available surface area for interaction.
SEM and EDX confirmed that ZnO nanoparticles were uniformly distributed and successfully incorporated into the coating.
UV-Vis analysis revealed that all samples maintained over 95 % transmittance in the visible range, preserving optical clarity important for items like face shields. Contact angle measurements showed that increasing ZnO content led to more hydrophobic surfaces, which can help repel respiratory droplets or fluids that carry pathogens.
Finally, TGA confirmed thermal stability across all concentrations. This thermal stability supports durability under conditions such as autoclaving or heat sterilization, which is relevant for PPE reuse protocols.
Fabric Type Matters
Antimicrobial performance varied depending on the substrate. Face mask fabrics, typically made from non-absorbent synthetic fibers, exhibited stronger antibacterial effects than cotton-based lab coats.
This contrast is attributed to better surface retention of the coating on smoother, less porous fabrics. The findings highlight how fabric structure can impact the ultimate performance of antimicrobial technologies in real-world applications.
PEG/ZnO coatings could also enhance hygiene in industries beyond healthcare, including food processing, public transit, and high-traffic public spaces.
ZnO’s designation as Generally Recognized as Safe (GRAS) by the FDA makes it suitable for everyday protective gear such as masks, gowns, and gloves.
By embedding antimicrobial agents directly into coating systems, these materials offer an added layer of protection in environments where surface contamination is a persistent concern.
A Step Forward in Infection Control
This study shows that PEG-ZnO nanocomposite coatings can meaningfully enhance the antimicrobial protection of PPE fabrics, turning a passive barrier into an active defense.
The 0.75 wt% formulation strikes the perfect balance between performance and material efficiency, maintaining surface transparency, thermal stability, and adhesion across different fabric types.
Looking ahead, future work should explore long-term durability, environmental safety, broader antimicrobial spectra, and real-world performance across different usage conditions.
With hospital-acquired infections still posing a major global threat, smart materials like these represent a practical, scalable way to make everyday protective gear safer for healthcare workers and patients.
Journal Reference
Reasmyraj S, et al. (2025). Advanced antimicrobial coatings for PPE: synergistic effects of polyethylene glycol and ZnO nanoparticles. Journal of Coatings Technology and Research. DOI: 10.1007/s11998-025-01168-7
