Pulp-Paperworld Magazine Issue 3
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Transcript of Pulp-Paperworld Magazine Issue 3
PULP-PAPERWORLD www.pulp-paperworld.com January 2011
Professional Tools and Equipment for Paper Machine Clothing
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T : +31 313 652 215 - F: +31 313 654 068 - E: [email protected]
ABB opens New Facility in Shanghai China.
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Mondi @ Paperworld 2011
IMERYS Pigments for Paper-MULTILAYER COATING CONCEPTS:IS IT
TIME FOR A NEW APPROACH?
ABB to deliver automation and electrical systems for paper mill in Philippines
Complete automation and electrification package
will optimize productivity and energy efficiency for
Schweitzer – Mauduit’s new paper machine
ABB announced that it recently won an order from Schweitzer – Mauduit International
Inc., to provide automation and electrification systems for its greenfield specialty paper mill in
Batangas, in the Philippines.
Schweitzer-Mauduit International, Inc. is a diversified producer of premium
specialty papers to the tobacco sector; it also manufactures specialty papers for other applications. The Batangas mill will produce
Reconstituted Tobacco Leaf (RTL), a specialty product that helps cigarette manufacturers to recycle their by-products while also providing a tool that facilitates them to meet regulatory
requirements.
The new paper machine to be installed will have a capacity of 30,000 tons per year and is
scheduled to be operational by November 2011.
ABB was awarded the contract for its knowledge, expertise and experience in the
Pulp and Paper Industry and the latest Product and System offerings which provide seamless integration of mill operations and optimized
energy efficiencies.The electrification delivery includes air insulated switchgear, Onan Transformers, and low voltage
Motor Control Centers with drives, Softstarters and low voltage motors. The automation scope
of supply includes a comprehensive DCS (distributed control system) based on extended
automation System 800xA with AC800M Controllers , Process Portal Operator Stations
with complete Profibus integration for the mill. The QCS (Quality Control Systems) delivery
includes the popular NP700 Network platform with Moisture, Basis Weight and Infrared
measurements. ABB’s local operations in Singapore and
Philippines will execute the project. Installation and commissioning is scheduled for the second
quarter of 2011.
Schweitzer-Mauduit and its subsidiaries conduct business in over 90 countries and employ 2,900
people worldwide, with operations in the United States, France, Brazil, Philippines, Indonesia,
Canada and China.
ABB (http://www.abb.com/) is a leader in power and automation technologies that enable utility and industry customers to improve their
performance while lowering environmental impact. The ABB Group of companies operates
in around 100 countries and employs about 117,000 people.
IMERYS Pigments for Paper www.imerys-paper.com
4 5
This acquisition further reinforces our ability to do this in a number of important ways:
It improves the security of supply for our customers. The combination
of IRCC and PPSA in Brazil provides a focussed and committed team
devoted to maximising the performance, quality and efficiency of the
world’s largest single source production operation. The enhanced
production capabilities give added security and also give us the
opportunity to focus on the key strengths of each element of the
Brazilian operation to maximise the benefit to our customers. Further,
the addition of the PPSA port facilities to our existing operations
provides increased capacity, flexibility and security of supply.
Product form standardisation will allow us to focus on the lowest
practicable environmental footprint.
It broadens the reserve position to better match our raw material
resources to the product portfolio allowing us to make our products
with minimum processing. The combined resources will allow us to
make highly efficient use of the reserve to produce a wide ranging
portfolio. IRCC and PPSA reserves are complementary and together
provide the full range of products required for the key segments
identified by IMERYS. Looking forward, the newly expanded reserves
will enhance IMERYS’ ability to develop our product range to meet
the future needs of the industry.
The newly expanded reserves will secure the long-term availability
of kaolin from Brazil which further strengthens our long-term
quality position. Additionally economies of scale can be leveraged
to reinforce the high record of quality consistency of PPSA and IRCC.
Access to the reserves of PPSA and the combination of their mining
with IRCC reserves extends the long term availability of IMERYS’
world class kaolin resources. Together these reserves constitute an
outstandingly wide and diversified range of raw materials for paper
production.
Continued overleaf
Reliability:
Sustainability:
Products:
Quality:
Quantity:
The recent acquisition of PPSA by the IMERYS Pigments for Paper group
is a significant move in our strategy to remain one of the leading suppliers
of kaolin to the worldwide paper industry but it is also a tangible sign of the
continuation of IMERYS’ commitment to the paper industry to ensure sustainable
long term supplies of high quality kaolin. Our paper markets are changing.
However, kaolin still constitutes an important strategic raw material for the
industry and we strongly believe that there is a long term requirement by the
paper industry for the quality attributes offered by Brazilian kaolin. Our
investment is a demonstration of our commitment to make sure we have the
reserves and assets that are required to maintain the quality, reliability and
service associated with our products. We believe kaolin has a long term future,
for segments that require the functionality that kaolin brings either alone or in
association with calcium carbonate. This investment will allow IMERYS to better
serve key coated paper and packaging segments and the combination of assets
in Brazil along with our assets in the USA and UK will also facilitate further
development of our high brightness filler kaolin portfolio for uncoated
mechanical and other paper grades.
A world class pigment supplier requires a combination of a number of key
attributes. Key amongst these is the ability to offer reliably and sustainably the
right products at the right quality in the right quantities at the right cost.
IRCC & PPSAA perfect combination
IMERYS Pigments for Paper www.imerys-paper.com
4 5
This acquisition further reinforces our ability to do this in a number of important ways:
It improves the security of supply for our customers. The combination
of IRCC and PPSA in Brazil provides a focussed and committed team
devoted to maximising the performance, quality and efficiency of the
world’s largest single source production operation. The enhanced
production capabilities give added security and also give us the
opportunity to focus on the key strengths of each element of the
Brazilian operation to maximise the benefit to our customers. Further,
the addition of the PPSA port facilities to our existing operations
provides increased capacity, flexibility and security of supply.
Product form standardisation will allow us to focus on the lowest
practicable environmental footprint.
It broadens the reserve position to better match our raw material
resources to the product portfolio allowing us to make our products
with minimum processing. The combined resources will allow us to
make highly efficient use of the reserve to produce a wide ranging
portfolio. IRCC and PPSA reserves are complementary and together
provide the full range of products required for the key segments
identified by IMERYS. Looking forward, the newly expanded reserves
will enhance IMERYS’ ability to develop our product range to meet
the future needs of the industry.
The newly expanded reserves will secure the long-term availability
of kaolin from Brazil which further strengthens our long-term
quality position. Additionally economies of scale can be leveraged
to reinforce the high record of quality consistency of PPSA and IRCC.
Access to the reserves of PPSA and the combination of their mining
with IRCC reserves extends the long term availability of IMERYS’
world class kaolin resources. Together these reserves constitute an
outstandingly wide and diversified range of raw materials for paper
production.
Continued overleaf
Reliability:
Sustainability:
Products:
Quality:
Quantity:
The recent acquisition of PPSA by the IMERYS Pigments for Paper group
is a significant move in our strategy to remain one of the leading suppliers
of kaolin to the worldwide paper industry but it is also a tangible sign of the
continuation of IMERYS’ commitment to the paper industry to ensure sustainable
long term supplies of high quality kaolin. Our paper markets are changing.
However, kaolin still constitutes an important strategic raw material for the
industry and we strongly believe that there is a long term requirement by the
paper industry for the quality attributes offered by Brazilian kaolin. Our
investment is a demonstration of our commitment to make sure we have the
reserves and assets that are required to maintain the quality, reliability and
service associated with our products. We believe kaolin has a long term future,
for segments that require the functionality that kaolin brings either alone or in
association with calcium carbonate. This investment will allow IMERYS to better
serve key coated paper and packaging segments and the combination of assets
in Brazil along with our assets in the USA and UK will also facilitate further
development of our high brightness filler kaolin portfolio for uncoated
mechanical and other paper grades.
A world class pigment supplier requires a combination of a number of key
attributes. Key amongst these is the ability to offer reliably and sustainably the
right products at the right quality in the right quantities at the right cost.
IRCC & PPSAA perfect combination
76
IMERYS Pigments for Paper
Importantly this acquisition also reinforces our ability to deliver
consistent quality cost effectively. Product range optimisation to
give a product portfolio well suited to the reserves will allow us to
ensure a sustainable low cost production platform. Increased volume
throughput will allow efficient utilisation of current production
assets and production facilities to maintain the strong cost position
of high quality Brazilian kaolin in the global market.
As well as these great attributes the interface with our customers is
of huge importance and the acquisition of PPSA also brings benefits
to us here. The combination of PPSA and IRCC will give us improved
market coverage. Furthermore it will allow us continuing focus on
technical service and applications development due to greater volume;
IMERYS has long been recognised as a technical leader in the application
of pigments in papermaking and at a time when all costs are under
pressure greater volume will support our ability to continue in this
role. Combining the existing strong presence of PPSA in Asia and
Brazil with IMERYS’ current involvement in the European and North
American markets generates a supplier with improved global reach.
This combination of PPSA and IRCC will provide enhanced geographical
market coverage which will lead to significant benefits for customers.
Last but not least our ability to get our products to customers in
good condition at the right time is enhanced through the combination
of PPSA and IRCC which will further optimise logistics for the global
market. Better use of regional distribution infrastructure will lead to
improved throughputs and utilisation and will help secure the low
cost operating philosophy. Optimisation of port facilities in Brazil
provides increased security as well as additional opportunities to
manage throughput effectively at peak times, allowing optimisation
of shipping, improved utilisation of vessels and increased flexibility
to manage variations in the supply chain.
The acquisition of PPSA is a major step to reinforce our Brazilian
operations and they are an ever more important element of IMERYS’
global kaolin supply strategy. However this does not mean that our
other existing production sites are losing their importance to IMERYS.
The North American and UK production operations remain important
due to the different nature of the reserves, products supplied and
markets served. Additionally their location in the world’s major
established paper production regions provides added security to
IMERYS’ global supply chain.
Cost:
IRCC and PPSA Kaolins High Performance….Naturally!Kaolins have been produced at IRCC and PPSA
since the mid 1990’s and have become firmly
established as the high quality products of
choice for the global paper market. The
principal strengths of these products lie in
the raw material itself. “Natural engineering”
delivers a combination of high brightness,
narrow particle size distribution and low
abrasion which cannot be matched sustainably
from other global reserves.
Brazilian Kaolins in CoatingThe combination of narrow particle size distribution and highbrightness is a feature of all IRCC and PPSA products and helps deliver improved light scatter and optical performance in a widerange of coating applications.
In coating applications the need to balance gloss developmentwith high brightness can often be challenging. Traditionally thekaolin imparts gloss, coverage and printability while carbonateimparts brightness. A key strength of Brazilian engineered gradesis the ability to shift this balance delivering improved optical performance for a given level of kaolin in the recipe. This can helppapermakers meet the market demands for brightness at higherkaolin levels resulting in improved printability in both offset androtogravure applications.
Alternatively the optical benefits can be used to reduce costs. Forexample reducing the amount of optical brightening agent neededand in some geographies, offsetting the need for expensive opacifierssuch as Calcined clay and Ti02.
The rheology of Brazilian kaolins also tends to be superior to thatfor “engineered” products with similar steepness and shape fromother global reserves.
This enables higher pigment slurry solids to be achieved andtranslates into higher colour solids in coating applications. Thiscan be particularly important for Metered Size Press (MSP) applications where the runnability window at high speeds can be limited. Coating at high solids together with the generation of an open coating structure can also help reduce drying energy.
Brazilian Kaolins in FillingThe combination of a coarse, steep particle size distribution together with high brightness and low abrasion give Brazilian filler grades a unique balance of properties.
The coarse and steep particle size can help machine runnabilitythrough improved dewatering, better retention and good paperstrength, while the low abrasion is good for wire life. Paper qualitycan also be improved through the combination of high naturalbrightness and decreased absorption. Brazilian filler grades areclose to 88 ISO brightness whereas many standard kaolin fillersare 83 ISO or lower.
For SC papers, these clays can be used to produce high brightnessSC-A+ grades under acid conditions without the compromise insurface properties and ink demand normally seen in neutral papermaking. Alternatively the scatter and brightness benefitscan be traded for cost reduction through reduced pulp bleaching.Additionally, Brazilian fillers have a strong technical fit as fillersfor LWC base papers where high loadings can be achieved resulting in benefits to surface quality after coating.
SummaryThe IRCC- PPSA platform is without doubt the
leading production facility globally for
sustainable high quality engineered kaolins
which deliver unmatched, cost- efficient
performance in a wide range of paper making
and paper coating applications.
Carbonates
CoverageGood
Coverage, PPS
Kaolin
CoveragePoor
High
Brig
htne
ss
Low
Engineered Kaolins can helpshift this balance
Coverage, PPSGloss
StiffnessPrint Quality
Key trade-off isgenerating brightnesswithout adverselyaffecting surface qualityand printability
Standard Quality
High Bright Quality
Standard Quality
High Bright Quality
Standard Quality
Brig
htne
ss
StandardQuality
HighBright
Quality
Low (Worst)High (Worst)
Standard SC Kaolin
Brazilian Fillers
GCC
Calcined Clay
PCC
NeutralCombinations
Low (Best)High (Best)
Sheet DemandInk Demand
0
200
400
600
800
1000
1200
1400
1600
1800
10 100 1000 10000
Brazilian Engineered kaolin 71 wt%
North American Engineered kaolin 67 wt%
mPa
.sVis
cosi
ty, m
Pa.s
Shear rate, s-1
Filler Requirement• Coarse & Steep PSD• Coarse & Steep PSD• Steep PSD• Low Abrasion
Runnability• Fast Dewatering• High Filler Loading• Good Paper Strength• Long Wire Life
Strengthsof Brazillian Kaolin for Paper
www.imerys-paper.com
76
IMERYS Pigments for Paper
Importantly this acquisition also reinforces our ability to deliver
consistent quality cost effectively. Product range optimisation to
give a product portfolio well suited to the reserves will allow us to
ensure a sustainable low cost production platform. Increased volume
throughput will allow efficient utilisation of current production
assets and production facilities to maintain the strong cost position
of high quality Brazilian kaolin in the global market.
As well as these great attributes the interface with our customers is
of huge importance and the acquisition of PPSA also brings benefits
to us here. The combination of PPSA and IRCC will give us improved
market coverage. Furthermore it will allow us continuing focus on
technical service and applications development due to greater volume;
IMERYS has long been recognised as a technical leader in the application
of pigments in papermaking and at a time when all costs are under
pressure greater volume will support our ability to continue in this
role. Combining the existing strong presence of PPSA in Asia and
Brazil with IMERYS’ current involvement in the European and North
American markets generates a supplier with improved global reach.
This combination of PPSA and IRCC will provide enhanced geographical
market coverage which will lead to significant benefits for customers.
Last but not least our ability to get our products to customers in
good condition at the right time is enhanced through the combination
of PPSA and IRCC which will further optimise logistics for the global
market. Better use of regional distribution infrastructure will lead to
improved throughputs and utilisation and will help secure the low
cost operating philosophy. Optimisation of port facilities in Brazil
provides increased security as well as additional opportunities to
manage throughput effectively at peak times, allowing optimisation
of shipping, improved utilisation of vessels and increased flexibility
to manage variations in the supply chain.
The acquisition of PPSA is a major step to reinforce our Brazilian
operations and they are an ever more important element of IMERYS’
global kaolin supply strategy. However this does not mean that our
other existing production sites are losing their importance to IMERYS.
The North American and UK production operations remain important
due to the different nature of the reserves, products supplied and
markets served. Additionally their location in the world’s major
established paper production regions provides added security to
IMERYS’ global supply chain.
Cost:
IRCC and PPSA Kaolins High Performance….Naturally!Kaolins have been produced at IRCC and PPSA
since the mid 1990’s and have become firmly
established as the high quality products of
choice for the global paper market. The
principal strengths of these products lie in
the raw material itself. “Natural engineering”
delivers a combination of high brightness,
narrow particle size distribution and low
abrasion which cannot be matched sustainably
from other global reserves.
Brazilian Kaolins in CoatingThe combination of narrow particle size distribution and highbrightness is a feature of all IRCC and PPSA products and helps deliver improved light scatter and optical performance in a widerange of coating applications.
In coating applications the need to balance gloss developmentwith high brightness can often be challenging. Traditionally thekaolin imparts gloss, coverage and printability while carbonateimparts brightness. A key strength of Brazilian engineered gradesis the ability to shift this balance delivering improved optical performance for a given level of kaolin in the recipe. This can helppapermakers meet the market demands for brightness at higherkaolin levels resulting in improved printability in both offset androtogravure applications.
Alternatively the optical benefits can be used to reduce costs. Forexample reducing the amount of optical brightening agent neededand in some geographies, offsetting the need for expensive opacifierssuch as Calcined clay and Ti02.
The rheology of Brazilian kaolins also tends to be superior to thatfor “engineered” products with similar steepness and shape fromother global reserves.
This enables higher pigment slurry solids to be achieved andtranslates into higher colour solids in coating applications. Thiscan be particularly important for Metered Size Press (MSP) applications where the runnability window at high speeds can be limited. Coating at high solids together with the generation of an open coating structure can also help reduce drying energy.
Brazilian Kaolins in FillingThe combination of a coarse, steep particle size distribution together with high brightness and low abrasion give Brazilian filler grades a unique balance of properties.
The coarse and steep particle size can help machine runnabilitythrough improved dewatering, better retention and good paperstrength, while the low abrasion is good for wire life. Paper qualitycan also be improved through the combination of high naturalbrightness and decreased absorption. Brazilian filler grades areclose to 88 ISO brightness whereas many standard kaolin fillersare 83 ISO or lower.
For SC papers, these clays can be used to produce high brightnessSC-A+ grades under acid conditions without the compromise insurface properties and ink demand normally seen in neutral papermaking. Alternatively the scatter and brightness benefitscan be traded for cost reduction through reduced pulp bleaching.Additionally, Brazilian fillers have a strong technical fit as fillersfor LWC base papers where high loadings can be achieved resulting in benefits to surface quality after coating.
SummaryThe IRCC- PPSA platform is without doubt the
leading production facility globally for
sustainable high quality engineered kaolins
which deliver unmatched, cost- efficient
performance in a wide range of paper making
and paper coating applications.
Carbonates
CoverageGood
Coverage, PPS
Kaolin
CoveragePoor
High
Brig
htne
ss
Low
Engineered Kaolins can helpshift this balance
Coverage, PPSGloss
StiffnessPrint Quality
Key trade-off isgenerating brightnesswithout adverselyaffecting surface qualityand printability
Standard Quality
High Bright Quality
Standard Quality
High Bright Quality
Standard Quality
Brig
htne
ss
StandardQuality
HighBright
Quality
Low (Worst)High (Worst)
Standard SC Kaolin
Brazilian Fillers
GCC
Calcined Clay
PCC
NeutralCombinations
Low (Best)High (Best)
Sheet DemandInk Demand
0
200
400
600
800
1000
1200
1400
1600
1800
10 100 1000 10000
Brazilian Engineered kaolin 71 wt%
North American Engineered kaolin 67 wt%
mPa
.sVis
cosi
ty, m
Pa.s
Shear rate, s-1
Filler Requirement• Coarse & Steep PSD• Coarse & Steep PSD• Steep PSD• Low Abrasion
Runnability• Fast Dewatering• High Filler Loading• Good Paper Strength• Long Wire Life
Strengthsof Brazillian Kaolin for Paper
www.imerys-paper.com
A World of Ideas . . . and Opportunities!Tissue World in Nice is THE BIG ONE: The original high-level meeting place for the world’s tissue paper business. By putting focuson this important fast moving consumer goods (FMCG) from both a market viewpoint as well as a technical development angle,Tissue World has become recognized as the world’s best conference for this dynamic sector.
Continuing the tradition of excellence, plans are now underway for the next BIG ONE: Tissue World 2011. Planned for late March28-31, 2011, Tissue World in Nice will offer the industry a great chance to exchange ideas and solutions.
For Suppliers to the Tissue Business –Your booth at the show is like setting up an office in the middle of all the decision makersin the world of tissue. This offers you a uniquely effective way to meet key people and discuss your products and solutions withthis important group of customers and potential customers.
To reserve your space on the floorplan, contact us NOW to get the best location.
For Tissue Makers – For tissue makers, or companies thinking about expanding in or entering the tissue business, this is greatopportunity to see all the world’s suppliers in one place at one time. Don’t miss it!
www.tissueworld.com
Organised By: Official Publication:
Tissue World
The Big OneNice in 2011
29-31 March 2011 (Exhibition)28-31 March 2011 (Conference)Acropolis,Nice, France
1110
IMERYS Pigments for Paper www.imerys-paper.com
In today’s fine paper environment we now believe
it can make more sense to use the functionality of
kaolin in precoating rather than in topcoating.
Modest amounts of kaolin combined with coarse
carbonates in precoating can improve quality and
give more degrees of freedom for reformulating
the topcoat to lower overall cost.
WHERE TO START
Selecting kaolins that are relatively coarse in particle size, with highaspect ratios and hence large plate diameters, are key to making thisapproach successful. Although kaolins from North America and Brazilare currently used in these formulations, there are select reserves inAsia which could, with the appropriate processing and know how,provide the necessary characteristics for successful precoating applications.
Good basepaper coverage is essential in maintaining quality inmulti-layer coating applications and can also offer potential for cost reduction. For example improved coverage could enable the use of lower cost rougher base stocks without the same tendencyfor mottle related issues. Additionally, improved precoat coveragecan facilitate the use of kaolin free topcoats especially on rougher basestocks. This can bring value through replacing high cost ultrafineglossing kaolin with lower cost precoating kaolin. Further savingscan then be made with respect to binder type and level in the topcoat recipe.
Using coarse platey kaolin in the precoat can improve the smooth-ness and delta gloss of matt or silk grades, with further benefitscoming from using the same kaolin to replace some coarse groundcalcium carbonate (GCC) in the top coat. This approach does not reduce the overall formulation cost for the coatings, but it can improve appearance.
BASEPAPER COVERAGE AND SURFACE CHARACTERISTICS
On a repeat basis, studies have shown that adding kaolin to the precoat reduces precoat roughness. Through extensive analysis using test such as laser profilometry, which assesses roughness at different length scales, and the more classic burnout test, we have demonstrated significantly improved coverage through this approach.This has positive implications for the roughness, sheet gloss, printgloss development, and mottle characteristics in the finished paper.In addition the improved coverage can result in reduced fibre pickduring coating, improving paper machine runnability and efficiencyand reducing the need to increase binder in the formulation.
When combined with GCC, high aspect ratio kaolins can also delivera bulky structure. This will further improve physical coverage andalso optical coverage through increased light scattering which canbe important on lower brightness basestocks (eg Board). However,the structure will retain a high degree of tortuosity, making fluidflow and migration of top coat binders more difficult.
Optical and coverage benefits of kaolin and GCC combinations have been evident in pilot scale studies of wood-free precoating. In the following example 30 parts of kaolin in the precoat show improvement in coverage when added to standard or engineered(steep) GCC in metered size press precoating, resulting in significantly improved smoothness. Kaolin addition to standard GCC typically has a minor effect on non-fluorescent brightness and increases opacity to a small degree going some towards achieving the level normally seen with engineered carbonates.
The key to improved coverage and bulk in the precoat lies in the aspect ratio of the kaolin; with higher shape kaolins giving betterstructuring and performance than lower shape kaolins.
These effects were further explored in a pilot coating study whichassessed a range of North American and Brazilian precoat kaolin options. These were used as low-level blend components with standard GCC in a blade-coated European wood-free application.
As before, coverage and smoothness improved compared to 100%GCC precoats when any of the kaolins were added to the recipe.More detailed analysis using scanning electron microscopy of papercross-sections showed these benefits arose mainly from the increased bulk giving significant increased coating thickness.,
1 CHRIS NUTBEEM & BENNY HALLAM OF IMERYS MINERALS LTD.
MULTILAYER COATING CONCEPTS:IS IT TIME FOR A NEW APPROACH?
THE MULTILAYER COATING MODEL
Much of the coated wood-free paper produced globally is multi-coated with two or three coating layers applied to each side of thepaper. The precoat and mid-coat layers provide physical coverage of the base and optical performance, while the top coat providessurface finish (gloss, silk, or matt) and printability.
The precoat in most coated fine paper applications today is basedon 100% coarse, inexpensive carbonate while the topcoat is generallybased on combinations of fine GCC and ultrafine glossing kaolin.However, in many regions, including much of Asia, topcoat kaolin is significantly more expensive than standard fine carbonates. Sothe trend among large mills is to reduce or eliminate glossing kaolin in top coating.
Low-kaolin or kaolin-free top coating is well established. However,developing sheet gloss and print gloss remains a challenge andoften requires significant reformulation in binders and additives. Porosity control and mottle also can be issues. Solving these problemscan lead to increased formulation costs, which can offset the savingsassociated with fine kaolin reduction, and brand image can suffer if printability issues persist.
In many cases, the problems associated with low-kaolin top coatingcan be linked to base paper effects, unevenness in the coating layers,and porosity characteristics. Achieving good base paper coveragecan resolve these issues. The best solution overall might be to focuson improving the precoat, rather than the top coat itself.
Historically, kaolin use in wood- free precoating has been low due tocost and brightness considerations, but the development of lower-cost, high-brightness platey kaolins is changing the dynamic. It maynow make sense from a cost performance standpoint to use kaolinfunctionality in precoating rather than in top coating.
PRECOATING INFLUENCES
Pigment selection for precoating markedly influences base papercoverage and the ability to provide a good barrier layer for top coatapplications. 25 parts of high aspect ratio kaolin added to a precoat,combined with coarse GCC and a latex starch recipe have proven tobe quite effective.
Example 01 Bulk and Coverage
Example 02 Metered Size Press Precoating
1 Significant improvements in coverage andPPS from kaolin addition to precoat.
1 Bulking effects of kaolin and standard GCCgive light scatter and opacity benefits vstandard GCC alone.
1 Further benefits from kaolin and narrow p.s.d. GCC together.
1110
IMERYS Pigments for Paper www.imerys-paper.com
In today’s fine paper environment we now believe
it can make more sense to use the functionality of
kaolin in precoating rather than in topcoating.
Modest amounts of kaolin combined with coarse
carbonates in precoating can improve quality and
give more degrees of freedom for reformulating
the topcoat to lower overall cost.
WHERE TO START
Selecting kaolins that are relatively coarse in particle size, with highaspect ratios and hence large plate diameters, are key to making thisapproach successful. Although kaolins from North America and Brazilare currently used in these formulations, there are select reserves inAsia which could, with the appropriate processing and know how,provide the necessary characteristics for successful precoating applications.
Good basepaper coverage is essential in maintaining quality inmulti-layer coating applications and can also offer potential for cost reduction. For example improved coverage could enable the use of lower cost rougher base stocks without the same tendencyfor mottle related issues. Additionally, improved precoat coveragecan facilitate the use of kaolin free topcoats especially on rougher basestocks. This can bring value through replacing high cost ultrafineglossing kaolin with lower cost precoating kaolin. Further savingscan then be made with respect to binder type and level in the topcoat recipe.
Using coarse platey kaolin in the precoat can improve the smooth-ness and delta gloss of matt or silk grades, with further benefitscoming from using the same kaolin to replace some coarse groundcalcium carbonate (GCC) in the top coat. This approach does not reduce the overall formulation cost for the coatings, but it can improve appearance.
BASEPAPER COVERAGE AND SURFACE CHARACTERISTICS
On a repeat basis, studies have shown that adding kaolin to the precoat reduces precoat roughness. Through extensive analysis using test such as laser profilometry, which assesses roughness at different length scales, and the more classic burnout test, we have demonstrated significantly improved coverage through this approach.This has positive implications for the roughness, sheet gloss, printgloss development, and mottle characteristics in the finished paper.In addition the improved coverage can result in reduced fibre pickduring coating, improving paper machine runnability and efficiencyand reducing the need to increase binder in the formulation.
When combined with GCC, high aspect ratio kaolins can also delivera bulky structure. This will further improve physical coverage andalso optical coverage through increased light scattering which canbe important on lower brightness basestocks (eg Board). However,the structure will retain a high degree of tortuosity, making fluidflow and migration of top coat binders more difficult.
Optical and coverage benefits of kaolin and GCC combinations have been evident in pilot scale studies of wood-free precoating. In the following example 30 parts of kaolin in the precoat show improvement in coverage when added to standard or engineered(steep) GCC in metered size press precoating, resulting in significantly improved smoothness. Kaolin addition to standard GCC typically has a minor effect on non-fluorescent brightness and increases opacity to a small degree going some towards achieving the level normally seen with engineered carbonates.
The key to improved coverage and bulk in the precoat lies in the aspect ratio of the kaolin; with higher shape kaolins giving betterstructuring and performance than lower shape kaolins.
These effects were further explored in a pilot coating study whichassessed a range of North American and Brazilian precoat kaolin options. These were used as low-level blend components with standard GCC in a blade-coated European wood-free application.
As before, coverage and smoothness improved compared to 100%GCC precoats when any of the kaolins were added to the recipe.More detailed analysis using scanning electron microscopy of papercross-sections showed these benefits arose mainly from the increased bulk giving significant increased coating thickness.,
1 CHRIS NUTBEEM & BENNY HALLAM OF IMERYS MINERALS LTD.
MULTILAYER COATING CONCEPTS:IS IT TIME FOR A NEW APPROACH?
THE MULTILAYER COATING MODEL
Much of the coated wood-free paper produced globally is multi-coated with two or three coating layers applied to each side of thepaper. The precoat and mid-coat layers provide physical coverage of the base and optical performance, while the top coat providessurface finish (gloss, silk, or matt) and printability.
The precoat in most coated fine paper applications today is basedon 100% coarse, inexpensive carbonate while the topcoat is generallybased on combinations of fine GCC and ultrafine glossing kaolin.However, in many regions, including much of Asia, topcoat kaolin is significantly more expensive than standard fine carbonates. Sothe trend among large mills is to reduce or eliminate glossing kaolin in top coating.
Low-kaolin or kaolin-free top coating is well established. However,developing sheet gloss and print gloss remains a challenge andoften requires significant reformulation in binders and additives. Porosity control and mottle also can be issues. Solving these problemscan lead to increased formulation costs, which can offset the savingsassociated with fine kaolin reduction, and brand image can suffer if printability issues persist.
In many cases, the problems associated with low-kaolin top coatingcan be linked to base paper effects, unevenness in the coating layers,and porosity characteristics. Achieving good base paper coveragecan resolve these issues. The best solution overall might be to focuson improving the precoat, rather than the top coat itself.
Historically, kaolin use in wood- free precoating has been low due tocost and brightness considerations, but the development of lower-cost, high-brightness platey kaolins is changing the dynamic. It maynow make sense from a cost performance standpoint to use kaolinfunctionality in precoating rather than in top coating.
PRECOATING INFLUENCES
Pigment selection for precoating markedly influences base papercoverage and the ability to provide a good barrier layer for top coatapplications. 25 parts of high aspect ratio kaolin added to a precoat,combined with coarse GCC and a latex starch recipe have proven tobe quite effective.
Example 01 Bulk and Coverage
Example 02 Metered Size Press Precoating
1 Significant improvements in coverage andPPS from kaolin addition to precoat.
1 Bulking effects of kaolin and standard GCCgive light scatter and opacity benefits vstandard GCC alone.
1 Further benefits from kaolin and narrow p.s.d. GCC together.
MULTILAYER COATING CONCEPTS:IS IT TIME FOR A NEW APPROACH?
12 13
IMERYS Pigments for Paper www.imerys-paper.com
MOTTLE CONSIDERATIONS
Mottle is one of the most common problems reported for coatedpapers and often occurs because of differences in porosity in thecoating layers or poor coverage of base paper. It follows that improving coverage in the precoat could be a powerful tool for reducing mottling tendency whether this be an optical type mottle on lower brightness basestocks or a gloss or print mottle.
In the following example the influence of the precoat on opticalmottle tendency was explored using whitelined chipboard with aPPS 10 roughness of 5.2m. In this case, 25 parts of high shape kaolin were added to a precoat recipe based on 60 grade GCC. A latex-starch recipe was used and colour solids of 66.5% were maintainedthroughout. Precoating was carried out at pilot scale and topcoating using a laboratory HelicoaterTM. A standard top coat based on 95grade GCC and 15 parts of glossing kaolin was applied and comparedwith another based on 100% ultrafine GCC.
Optical maps were generated using a computer scanner wheregreyscale images were collected and the variation assessed usingimage analysis techniques. The were lightly calendered to achieve a target gloss of approximately 40. The results show that using coarse high-shape kaolin in the precoat improved smoothness for the samepaper gloss level and improved print gloss development (delta gloss)without adverse changes in ink setting. Significant improvements indelta gloss, print abrasion (ink scuff), and opacity resulted when thesame coarse kaolin was used to partially replace the coarse carbonatein the bimodal low gloss top coat. Paper gloss and ink setting rateswere similar to those of the all carbonate reference. Overall, addingcoarse platey kaolin to the precoat provides low sheet roughness for a given target gloss, which helps with print gloss development.These kaolins also improve printability when used in the top coat.
INFLUENCE OF PRECOAT IN MATT/SILK WOOD-FREE
Producing a good matt or silk paper is really about finding the best compromise between often competing paper characteristics. Producers of matt and silk papers strive for good smoothness, low paper gloss, high bulk, and high print snap or delta gloss withoutoverly slow ink setting. This latter issue, particularly in low gloss papers, can cause ink scuff problems and printing press inefficiencies.
To see if modifying the precoat can influence the gloss-smoothnessbalance in low gloss applications and improve delta gloss withoutslowing ink setting rates, pilot coated base papers based on 100% 60 grade GCC and 60 grade GCC with 25% coarse platey Braziliankaolin were used to map these effects. In addition to applying astandard kaolin-free bimodal top coat, some of the coarse carbonateused to control gloss in the top coat was replaced with the samehigh shape kaolin used in the precoat. The coated papers werelightly calendered to achieve a target gloss of approximately 40.
The results show that using coarse high-shape kaolin in the precoat improved smoothness for the same paper gloss level andimproved print gloss development (delta gloss) without adversechanges in ink setting. Significant improvements in delta gloss,print abrasion (ink scuff), and opacity resulted when the samecoarse kaolin was used to partially replace the coarse carbonatein the bimodal low gloss top coat. Paper gloss and ink settingrates were similar to those of the all carbonate reference.
Overall, adding coarse platey kaolin to the precoat provides lowsheet roughness for a given target gloss, which helps with printgloss development. These kaolins also improve printability whenused in the top coat.
CONCLUSIONS
In today’s fine paper environment it can be advantageous to use the functionality of kaolin in precoating rather than in topcoatingto achieve superior basepaper coverage with increased bulk andlight scatter.
Good base paper coverage is essential in maintaining quality in multilayer coating applications and can reduce costs. Combiningkaolin and coarse carbonate can enhance the ability of the precoatto cover base coat roughness which could enable the use of lowercost rougher base stocks without the same tendency for mottle related issues. Improved precoat coverage can facilitate the use ofkaolin-free top coats, especially on rougher base stocks, reducingthe need for high-cost ultrafine glossing kaolin and offering potential for top coat binder reduction. Kaolin in precoating also improves print reducing the need for more expensive binders tocontrol printability. Additionally, coarse platey kaolin in the precoat helps smoothness and delta gloss in matt or silk grades,with further benefits coming from using the same kaolin to replace some coarse GCC in the top coat.
Overall it is evident that while carbonates can be made fine enough to deliver gloss they cannot be modified sufficiently inshape to improve coverage. As a result, we conclude that thevalue of kaolin in today’s cost focussed coated fine paper marketis therefore in its ability to cover the surface, not in its ability togenerate paper gloss. q
INFLUENCE OF PRECOAT IN GLOSSY WOOD-FREE
Paper and print gloss development remain the key challenges whenusing kaolin-free top coats in multilayer coating applications.
A 100% GCC top coat is often slightly deficient in sheet gloss andprint gloss compared to more conventional recipes containing 20-30parts of ultrafine kaolin. Increasing the sheet and print gloss in thekaolin-free systems can be challenging and can often mean changingto finer binders with lower ink interactivity and/ or increasing calendarload, which can be detrimental to opacity and stiffness.
Using high shape kaolins in the precoat can help change these dynamics. In numerous studies benefits to print gloss and opacityhave been observed through this approach which gives more degrees of freedom for topcoat design.
In one case study, the topcoats based on 100 parts ultrafine GCC,were applied to a range of kaolin-containing precoats and a reference GCC-only precoat. Coatings were applied at 69% solids in the laboratory. The coated papers were then laboratory supercalendered to give gloss levels of close to 75 with the reference system. The results are shown in the following table andindicate benefits to print gloss when the kaolin free-topcoat wasapplied onto kaolin- containing precoats. In this study sheet glosswas not improved, through kaolin addition to the precoat, but itshould be noted that the basepaper was already reasonably smoothwith a PPS of 5.6. On rougher basestocks (eg white lined Board) 2-3 units improvement in sheet gloss have been observed throughkaolin addition to the precoat.
Opacity was also improved which can be beneficial if harder calendering is required to restore gloss or for lighter weight applications where opacity can often be a critical parameter. Addinglow levels of kaolin to the precoat tended to have relatively little effect on finished paper brightness after application of the top coat,partly because bulk structuring improves light scattering. This alsohas implications for opacity; kaolin addition in the precoat can allow more freedom for adjusting calendering to regain gloss.
Although non-UV brightness is largely unaffected by kaolin in theprecoat, fluorescence can be reduced, resulting in lower overall UVbrightness. This drop is more than offset by kaolin removal from thetop coat and could be adjusted by changing the balance betweenoptical brightening additives in pre- and top coat.
Example 04 Technical Needs in Low Gloss Papers
Example 03
Mo
ttle in Do
uble Co
ated Board
1 Producing a good matt or silk paper is really about finding the best compromise between often competing paper characteristics
1 Achieving good print snap without slowing ink setting and achieving low sheet gloss with good smoothness and bulk are often key challenges in these applications
1 Here we see how coarse platey kaolin in the precoat as well asthe topcoat can shift this balance.
1 Precoat kaolins can also be used to good effect in Matt/Silk Topcoating to replace coarse GCC.
1 Using kaolin in the precoat improves gloss and brightness, makes the board smoother and reduces optical mottle.
MULTILAYER COATING CONCEPTS:IS IT TIME FOR A NEW APPROACH?
12 13
IMERYS Pigments for Paper www.imerys-paper.com
MOTTLE CONSIDERATIONS
Mottle is one of the most common problems reported for coatedpapers and often occurs because of differences in porosity in thecoating layers or poor coverage of base paper. It follows that improving coverage in the precoat could be a powerful tool for reducing mottling tendency whether this be an optical type mottle on lower brightness basestocks or a gloss or print mottle.
In the following example the influence of the precoat on opticalmottle tendency was explored using whitelined chipboard with aPPS 10 roughness of 5.2m. In this case, 25 parts of high shape kaolin were added to a precoat recipe based on 60 grade GCC. A latex-starch recipe was used and colour solids of 66.5% were maintainedthroughout. Precoating was carried out at pilot scale and topcoating using a laboratory HelicoaterTM. A standard top coat based on 95grade GCC and 15 parts of glossing kaolin was applied and comparedwith another based on 100% ultrafine GCC.
Optical maps were generated using a computer scanner wheregreyscale images were collected and the variation assessed usingimage analysis techniques. The were lightly calendered to achieve a target gloss of approximately 40. The results show that using coarse high-shape kaolin in the precoat improved smoothness for the samepaper gloss level and improved print gloss development (delta gloss)without adverse changes in ink setting. Significant improvements indelta gloss, print abrasion (ink scuff), and opacity resulted when thesame coarse kaolin was used to partially replace the coarse carbonatein the bimodal low gloss top coat. Paper gloss and ink setting rateswere similar to those of the all carbonate reference. Overall, addingcoarse platey kaolin to the precoat provides low sheet roughness for a given target gloss, which helps with print gloss development.These kaolins also improve printability when used in the top coat.
INFLUENCE OF PRECOAT IN MATT/SILK WOOD-FREE
Producing a good matt or silk paper is really about finding the best compromise between often competing paper characteristics. Producers of matt and silk papers strive for good smoothness, low paper gloss, high bulk, and high print snap or delta gloss withoutoverly slow ink setting. This latter issue, particularly in low gloss papers, can cause ink scuff problems and printing press inefficiencies.
To see if modifying the precoat can influence the gloss-smoothnessbalance in low gloss applications and improve delta gloss withoutslowing ink setting rates, pilot coated base papers based on 100% 60 grade GCC and 60 grade GCC with 25% coarse platey Braziliankaolin were used to map these effects. In addition to applying astandard kaolin-free bimodal top coat, some of the coarse carbonateused to control gloss in the top coat was replaced with the samehigh shape kaolin used in the precoat. The coated papers werelightly calendered to achieve a target gloss of approximately 40.
The results show that using coarse high-shape kaolin in the precoat improved smoothness for the same paper gloss level andimproved print gloss development (delta gloss) without adversechanges in ink setting. Significant improvements in delta gloss,print abrasion (ink scuff), and opacity resulted when the samecoarse kaolin was used to partially replace the coarse carbonatein the bimodal low gloss top coat. Paper gloss and ink settingrates were similar to those of the all carbonate reference.
Overall, adding coarse platey kaolin to the precoat provides lowsheet roughness for a given target gloss, which helps with printgloss development. These kaolins also improve printability whenused in the top coat.
CONCLUSIONS
In today’s fine paper environment it can be advantageous to use the functionality of kaolin in precoating rather than in topcoatingto achieve superior basepaper coverage with increased bulk andlight scatter.
Good base paper coverage is essential in maintaining quality in multilayer coating applications and can reduce costs. Combiningkaolin and coarse carbonate can enhance the ability of the precoatto cover base coat roughness which could enable the use of lowercost rougher base stocks without the same tendency for mottle related issues. Improved precoat coverage can facilitate the use ofkaolin-free top coats, especially on rougher base stocks, reducingthe need for high-cost ultrafine glossing kaolin and offering potential for top coat binder reduction. Kaolin in precoating also improves print reducing the need for more expensive binders tocontrol printability. Additionally, coarse platey kaolin in the precoat helps smoothness and delta gloss in matt or silk grades,with further benefits coming from using the same kaolin to replace some coarse GCC in the top coat.
Overall it is evident that while carbonates can be made fine enough to deliver gloss they cannot be modified sufficiently inshape to improve coverage. As a result, we conclude that thevalue of kaolin in today’s cost focussed coated fine paper marketis therefore in its ability to cover the surface, not in its ability togenerate paper gloss. q
INFLUENCE OF PRECOAT IN GLOSSY WOOD-FREE
Paper and print gloss development remain the key challenges whenusing kaolin-free top coats in multilayer coating applications.
A 100% GCC top coat is often slightly deficient in sheet gloss andprint gloss compared to more conventional recipes containing 20-30parts of ultrafine kaolin. Increasing the sheet and print gloss in thekaolin-free systems can be challenging and can often mean changingto finer binders with lower ink interactivity and/ or increasing calendarload, which can be detrimental to opacity and stiffness.
Using high shape kaolins in the precoat can help change these dynamics. In numerous studies benefits to print gloss and opacityhave been observed through this approach which gives more degrees of freedom for topcoat design.
In one case study, the topcoats based on 100 parts ultrafine GCC,were applied to a range of kaolin-containing precoats and a reference GCC-only precoat. Coatings were applied at 69% solids in the laboratory. The coated papers were then laboratory supercalendered to give gloss levels of close to 75 with the reference system. The results are shown in the following table andindicate benefits to print gloss when the kaolin free-topcoat wasapplied onto kaolin- containing precoats. In this study sheet glosswas not improved, through kaolin addition to the precoat, but itshould be noted that the basepaper was already reasonably smoothwith a PPS of 5.6. On rougher basestocks (eg white lined Board) 2-3 units improvement in sheet gloss have been observed throughkaolin addition to the precoat.
Opacity was also improved which can be beneficial if harder calendering is required to restore gloss or for lighter weight applications where opacity can often be a critical parameter. Addinglow levels of kaolin to the precoat tended to have relatively little effect on finished paper brightness after application of the top coat,partly because bulk structuring improves light scattering. This alsohas implications for opacity; kaolin addition in the precoat can allow more freedom for adjusting calendering to regain gloss.
Although non-UV brightness is largely unaffected by kaolin in theprecoat, fluorescence can be reduced, resulting in lower overall UVbrightness. This drop is more than offset by kaolin removal from thetop coat and could be adjusted by changing the balance betweenoptical brightening additives in pre- and top coat.
Example 04 Technical Needs in Low Gloss Papers
Example 03
Mo
ttle in Do
uble Co
ated Board
1 Producing a good matt or silk paper is really about finding the best compromise between often competing paper characteristics
1 Achieving good print snap without slowing ink setting and achieving low sheet gloss with good smoothness and bulk are often key challenges in these applications
1 Here we see how coarse platey kaolin in the precoat as well asthe topcoat can shift this balance.
1 Precoat kaolins can also be used to good effect in Matt/Silk Topcoating to replace coarse GCC.
1 Using kaolin in the precoat improves gloss and brightness, makes the board smoother and reduces optical mottle.
GAW Technologies obtains orders worth14 Million Euro
Chinese Paper Group Nine Dragons isrepeatedly relying on GAW know-how
The Austrian industrial plant constructor with world-wide excellent reputation GAW technolo-gies has received a very special order with a volume of 14 Mio. Euro from a longterm cus-tomer – the largest producer of containerboard products in China – Nine Dragons Paper, and takes an important part in the current produc-tion extension at several locations.
Paper Corporate Group of the richest self-made woman in the world Cheung Yan (also called Zhang Yin) founded Nine Dragons in 1995 and she reached the top of the richest people list in China only 11 years later. She also was the rich-est self-made woman in the world at that time. Zhang Yin recognized in time that the rise of the Chinese economy would result in an im-mense boost of paper-demand. She emigrated to the USA, started to collect waste paper on a grand scale and began a very successful export business where she shipped the raw material to China for recycling purposes.
Massive increase of the production capacity until 2011.
The Asian multinational paper company is planning to extend its production capacity significantly in modernizing and extending the existing paper machines and/or building new units at the locations in Taicang, Dongguan, Chongqing and Tianjin until end of 2011.
Besides that Nine Dragons is emphasizing its important role as a producer of papers basedon recovered/waste paper. In the course of these wide activities Nine Dragons is trustingonce again in the competence and know-how of GAW, being a reliable supplier for almost adecade already. An extraordinary sign of trust is
the fact that GAW has been involved in thedelivery of all the existing 34! paper machines of the customer.
GAW scope of delivery at Nine Dragons
GAW is delivering the wet-end chemicals, deinking chemicals, GCC wet grinding system, the coating colour preparation and the working stations as well as starch system for the papermachines PM21, 28, 32, 33 and 34. The start-ups of all units are planned in 2011.
By closure of these projects - according to Nine Dragons - the overall capacity of the group will increase to 11,1 Million tons per year, this corre-sponds to a capacity extension of 26%. For this
reason Nine Dragons is once more proving its strength as one of the most successful playerson the global paper-market.
For more information please contact:GAW technologies GmbH
Sigrid Tertinegg / marketingTel: +43 (0)316 2704 119
Fax: +43 (0316) 2704 [email protected]
Maximizing the performance of what you have, adding cutting edge technology toexisting systems or just fixing something that’s broken are all things pulp and papercompanies should expect from their automation and electrification partner withoutregard to the age of the system. The expectations for an industry pioneer like ABBhave never been higher and we can meet those expectations.www.abb.com/pulpandpaper
Should you expect support 25 years later?
Absolutely.
Mondi invites visitors to see, feel and smell their paper at Paperworld 2011,
January 29th – February 1st in Frankfurt
DNS® and Nautilus® ReFresh TRIOTEC — new products from Mondi’s digital printing and environmental paper portfolios — will be showcased along with Mondi’s entire uncoated fine paper portfolio.
Mondi, a global leader in the manufacturing of paper and packaging, has taken a
playful approach to this year’s Paperworld with the intriguing invitation to visitors to see, feel,
and smell Mondi papers.
Mondi’s focus on exploring the senses filters into the Pernod
Ricard-sponsored cocktail bar that will open in the late-afternoon at the Mondi booth D21, Hall 4. Mondi will hold extended cocktail hours until 8pm on Monday, January
31, where visitors can enjoy refreshments while talking with
Mondi representatives and exploring the aesthetic, tactile
and fragrant qualities of Mondi papers.
“This is a fun way to encourage people to explore paper and
the creative applications that are possible with new printing and converting technologies,” say
Johannes Klumpp Marketing and Sales Director Mondi Uncoated Fine Paper. “Along with the in-
troduction of new products from the DNS® and Color Copy rang-es and the launch of Nautilus® ReFresh TRIOTEC, this year our
aim is to show customers how to achieve excellent results for par-ticular applications when using
specified Mondi papers.”
Mondi invites visitors to see, feel and smell their paper at Paperworld 2011,
January 29th – February 1st in Frankfurt
DNS® and Nautilus® ReFresh TRIOTEC — new products from Mondi’s digital printing and environmental paper portfolios — will be showcased along with Mondi’s entire uncoated fine paper portfolio.
“This is a fun way to encourage people to explore paper and
the creative applications that are possible with new printing and converting technologies,” say
Johannes Klumpp Marketing and Sales Director Mondi Uncoated Fine Paper. “Along with the in-
troduction of new products from the DNS® and Color Copy rang-es and the launch of Nautilus® ReFresh TRIOTEC, this year our
aim is to show customers how to achieve excellent results for par-ticular applications when using
specified Mondi papers.”
Overlapping with Mondi’s long-standing commitment to
environmentally sound products, Mondi’s uncoated
fine paper product range is tai-lored for applications in 7 core
areas of expertise:
office communication, digital print communication,
digital print publishing, digital print imaging, transactional
printing, offset printing, value added converting.
Customers will have the oppor-tunity to ask Mondi representa-tives about the specific papers
qualities that are recommended for certain applications at
Paperworld 2011.
ABB inaugurates new manufacturing base for Pulp and Paper Business in China
ABB, the leading power and automation technology group, held here today an opening ceremony for its Quality Control Systems (QCS) and Web Imaging Systems (WIS) factory. The state-of-the-art facility becomes ABB’s only manufacturing base for QCS
and WIS worldwide. The move further optimizes the company’s global business footprint and exemplifies its “in China, for the world” strategy. The factory will
deliver first class products and solutions to customers in Asia and around the world, addressing the demands of
the global papermaking market.
Tobias Becker, head of the Process Automation Division, ABB North Asia Region and ABB China, said, “Emerging markets such as China, Brazil, and Indonesia
became growth engines of the global paper industry. Their rapid development is fuelling demand for all kinds of automation technologies and is establishing the latest industry trends. The commissioning of the new factory
is ABB Group’s most recent move to optimize our global business footprint. It allows us to promptly respond to both Asia and the global markets, and sustainably provide leading products and services to our global
customers.”
The new factory, located in the Shanghai Pudong New Area, covers 9000 square meters. The ABB Pulp and
Paper Business Unit will transfer its entire QCS and WIS
manufacturing business from its Ireland and Finland facilities to the new location, making it the company’s
latest global manufacturing center.
ABB is the technology leader in the global paper industry, providing the most comprehensive automation,
measurement, and electrical equipment portfolio and solutions. ABB Pulp and Paper Business Unit invests
over 10% of its annual revenue in R&D and has invented a number of leading technologies and products,
including Induction xP, the innovative machine actuator, Optical Caliper Sensor, the revolutionary product for measuring sheet thickness, and Multi-variable
cross-direction control, the unique QCS technology. ABB is driving the development of paper automation technology with its advanced technology, solutions,
products, and top class services over decades.
Its full range of solutions, including electrical, open control, paper machine drive, collaborative production management, quality control, energy management, and web inspection, have been adopted by many large scale
papermakers worldwide, such as UPM-Kymmene, Stora Enso, APP etc.
QCS is the nervous system of the paper production line, decisive to the quality of paper products. ABB QCS controls production quality by analyzing the paper’s
moisture, thickness, gloss, and other physical parameters with various types of sensors, helping papermakers
reduce rejection rates and greatly improve economic returns. ABB WIS detects and reports defects, including
holes, spots, and streaks, through its web imaging solutions. It not only guarantees product quality, but
also helps papermakers adjust the operating process, to make right decisions of production and maintenance before problems arise, thereby remarkably improving
production efficiency and economic returns.
China’s paper industry has enjoyed fast growth in the past decade. In order to support this development, ABB
began establishing the local Pulp and Paper team as early as 1994 and set up branches in Beijing, Shanghai, and Guangzhou. It boasts the most comprehensive talent
pool and strongest service capabilities serving the paper industry in the country. By 2009, ABB had successfully
completed around 500 significant projects in China, building long-term partnerships with a large number
of local and global paper companies including Hengan Paper, Nine Dragons Paper, Lee & Man Paper, and
Huatai Group.
ABB (www.abb.com) is a leader in power and automation technologies that enable utility and industry customers to improve their performance while lowering
environmental impact. The ABB Group of companies operates in around 100 countries and employs about
117,000 people. ABB has a full range of business activities in China, including R&D, manufacturing, sales
and services, with 15,300 employees, 30 joint ventures and wholly owned companies, and an extensive sales and
service network across 60 cities.
FOR AND ABOUT PEOPLEAT PIGMENTS FOR PAPER
IMPA
CT
GLO
BA
L
ADDING VALUE TO PAPER – JUNE 2010
For and about peopleat Pigments for Paper
Europe
Tel: +358 20 757 7700�
Asia Pacific
Tel: +65 67 99 60 60� � Internet:
www.imerys-paper.com
N. America
Tel: +1 770 594 0660�
S. America
Tel: +55 11 2133 0055�
ADDING VALUE TO PAPER
design: sheardhudson.com
BTG - Solve print mottleHigh - Tech blade puts an end
to mottle woesTrials prove that soft-tipped "elastomer-based" - coating blades can be the solution to persistent coating problems like surface mottling, which compromise product quality.
Read more
Mill saves money and reputation thanks to mottle reduction
Print mottle spoils paper quality and undermines a mill’s efficiency
and productivity. But while not every mill can upgrade to state-of-the-art coating equipment, a trial at a prominent mill in the Americas confirms that a simple change to
soft-tipped coating blades can be the solution.
The latest innovations in coating equipment has made producing coated fine
paper much easier for those mills lucky enough to have the resources to make a major capital investment in brand new plant. But for everyone else – and that
means the vast majority of paper producers – getting top quality, competitive products out of existing machines remains a daily
challenge. Sometimes, though, the solution to persistent production problems proves
to be simpler, cheaper, and easier than expected.
One of our coated paper clients in the Americas was experiencing chronic
problems with paper mottling, which was impacting productivity and profitability. The mill uses an off-machine coater that was originally installed in the early ‘70s,
and partly refurbished a few years ago with new drying hoods, soft calenders and a center winder. The original and manual
blade coating heads had not been upgraded and were still in place – so that while paper quality had increased, thanks to the newer equipment, the mill was struggling without
success to eliminate paper mottle.
To tackle the problem, our engineers worked closely with the mill’s own
production staff. The solution: a move to an advanced elastomer-tipped coating
blade, which not only resolved the mottle problem on the mill’s most difficult grades, but significantly improved CD coatweight
profiles and reel structure.
In general, the point of the coating process is to create a product that, together with
applied inks, will serve as a visual medium, conveying artwork and messages to the consumers through publicity material,
information products, packaging solutions and more. The visual appearance of the printed surface of the paper projects a
perceived quality level – and influences the consumer in subtle and subjective ways.
So high-end products rely heavily on high-quality papers.
In fact, the fault known as ‘mottle’ does not actually describe any specific defect in the coated paper production process, but rather an undesirable end result that detracts from final printed image quality.
The effect is difficult to pin down in words – perhaps the best description would be a ‘non-uniformity’ where homogeneity
should prevail. Figures 1a and 1b illustrate the contrast between a clean, uniform end
result, and a print test showing mottle.
A mottled coating
Figure 1a: A uniform, high quality result Figure 1b: A mottled finish leads to rejected paper
As paper is, by definition, an imperfect substrate – and some papers more
so than others – applying coating to variable surfaces will inevitably result
in coated products that exhibit different characteristics. In addition, a wide range of different manufacturing problems can
ultimately lead to mottle, starting with fiber quality, and moving through refining and
formation at the wet end.The customer had already noticed that
mottling was worst on paper of higher basis weight. But while new equipment – particularly a new drying system and soft
nip calendering – had helped a lot, the mill was still losing 180 tons per year of
150-170gsm paper to unsightly mottling. The problem was made worse by the fact that the loss was in the form of returned paper from the mill’s customers – which was impacting its reputation as a reliable
supplier, as well as its bottom line.
Cont......
Putting innovation to workSince further plant upgrade simply wasn’t
an option, the mill asked us to see if we could find an innovative, ‘smart’ solution to the problem. In mid-2009, we began
collaborating and proposed running trials with our patented elastomer-based soft-
tip coating blade – a potential solution that had already chalked up some documented
successes in the area of paper mottle.
A simple change to a soft-tipped blade is saving the mill hundreds of thousands
of dollars each year, while reinforcing its reputation as a reliable supplier of high
quality papers
Every BTG Duroblade Soft-tip is precision-engineered to meet the exact requirements of each individual coater station, delivering high performance
through a process of ‘micro-contouring’ that occurs under the blade tip.
By slightly deforming at the point of highest specific pressure, the elastomer tip
gives better coating coverage on the highest points of the fiber surface. This prevents the large, localized variations in coating
thickness that can result in a mottled finish (see Figures 3a and 3b).
Figure 3a: A conventional hard-tip blade ‘scalps’ high spots
Figure 3b: BTG’s Duroblade® Soft-tip micro-contours the paper surface
In addition, it’s important to remember that thick layers of liquid coating dry at a slower rate than thinner layers, creating a different stratification of pigments and adhesive particles. By aggressively scraping the paper surface, hard blades effectively create peaks and troughs,
which result in variations in coating levels and ink receptivity – leading to mottle.
Figure 4: Dramatic improvement: samples of 170gsm paper, where the only difference was the type of blade used.
Dramatic savings – in money and reputation
Eight months into the soft-tip blade trial, the mill had not received a single complaint
from customers related to mottle. In monetary terms alone, that translated into savings of US$ 300,000 – not to mention reinstatement of the mill’s reputation as a
quality manufacturer. In addition, the mill has been able to move from a specially-formulated latex adhesive designed to counteract the chronic mottling with a
standard coating latex, saving a further US$ 100,000.
The elastomer-based soft-tip blade is also delivering longer blade life, for fewer blade
changes and less downtime.
Talk to your BTG representative about how our teams can work with you to find innovative solutions to your production problems. With our expertise, extensive hands-on experience, and leading-edge
products, the solution may be easier, and cheaper, than you think!
For more information, visit www.btg.com or contact your local sales company.
PULP & PAPER
RESPONSIBLE
TANK CLEANING
As leaders in the global supply of equipment which uses water and chemicals to clean tanks across a wide variety of industries we know some of the pressures facing the manufacture of pulp and paper. The large volumes of water consumed and effluent discharged requires an optimal approach to cleaning. At Scanjet Systems we call this responsible tank cleaning. This means we don’t just supply you with equipment to clean your tanks to the highest standard and in the shortest time, instead we take care to find a technical solution that will use the lowest volume of water and chemicals, that will enable maximum recycling of cleaning waters and that will release the lowest volume and concentration of effluent. We know how important it is for your process to be efficient and environmentally responsible and we appreciate water is a scarce resource. In our team we carry microbiologists, engineers and utilities specialists from the process industries who have the most experience in providing answers to your tank cleaning challenges. With offices based in the US, Europe and Asia Pacific we have additionally developed sales partners with specific pulp and paper industry expertise. Scanjet Systems is the global supplier but with locally placed partners .
OUR CONCEPT
– RESPONSIBLE TANK CLEANING
Scanjet Systems holds the largest range of tank cleaning machines for pulp and paper applications. Decisions on whether to supply internal or external gearing, electric, mechanical or air driven, single or multi nozzle will depend on the specific vessel application. In all cases machine reliability is paramount to cope with the intensive environment. In this respect the Scanjet experience of supplying tens of thousands into the marine/shipping market instils confidence since this is a mobile industry which operates globally with few people on board.
SCANJET SYSTEMS BENEFITS
REDUCING WATER USE
REDUCING MICROBIOLOGICAL LEVELS
IMPROVING RECYCLED PAPER PRODUCTION
INCREASING PERSONNEL SAFETY
The SC 40RT is a dual or four nozzle externally driven automated tank cleaning machine constructed of 316 stainless steel and other highly corrosion resistant materials. It employs a patented magnetic drive transmission thus reducing the need for costly seal replacements and potential failures when used in hazardous environments. The drive mechanism and other major components are external to the tank, resulting in easy maintenance and a high level of safety when the cleaning of hazadous products are
required.
TYPICAL APPLICATIONS
Ethanol fermenters Crude oil storage tanks Gasoline storage tanks
High density stock chest Large silos & dryers
Over-the-road tankers & railcars Reactors
Large Uni-Tanks
The SC 15TW is a 1.5” dual or four nozzle automated tank cleaning machine constructed of 316 stain-less steel and other highly corrosion resistant materials. It has a fixed to moving gear ratio of 47 to 49 allow-ing it to produce a homogenous 360deg pattern that is superior to that of any other rotating jet head in it’s class. It is an integrated turbine class type of tank cleaning machine and employs an adjustable turbine and flow through gearbox. The adjustable turbine allows the rota-
tion speed to be adjusted.
TYPICAL APPLICATIONS
Road and Rail tanker cleaning Portable cleaning for contractors
Fermenter tank cleaning Storage tank cleaning
Wine storage tanks & fermenters Brewery storage tanks & fermenters
SC 15TW
The SC 30T is a single nozzle mechanically programmable auto-mated tank cleaning machine constructed of 316 stainless steel and other highly corrosion resistant materials. It allows the operator to wash the tank in a full 360deg mode or to set the nozzle angle to wash the tank within a particular section. It also employs a patented magnetic drive transmission. The drive mechanism and other major components are external to the tank, resulting in easy maintenance
and a high level of safety.
TYPICAL APPLICATIONS
Ethanol fermenters Crude oil storage tanks Gasoline storage tanks
High density stock chest Large silos & dryers
Over-the-road tankers & railcars Reactors
Large Uni-Tanks
SC 30T
RELEVANT PRODUCTS
www.scanjetsystems.com
SC 40RT
Whatever you need, whether it’s a full scope of processes and products for the pulp, paper and power generation industries, millwide automation solutions or thesupport of a worldwide customer service network, our business is to deliver it.
Expect results is our promise to help you reach your goals.
“You need it, we deliver it.”
www.metso.com/pulpandpaper
Invitationto the world’s leading
Pulp & Paper event
May 17–19 2011Stockholm, Sweden
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The essence of the con-cept is simple but im-
portant – making it easierfor people to meet.
Gone are the separateexhibition halls and distantconference locations aswell as conference fees. In-stead we have, after liste-ning to both exhibitors andvisitors, chosen to focus onthe following key words:
Time Efficiency
Closeness to Customers
Power to Influence
The heart of the event will be the three squares in Hall A. The squares will hold all major conference activitiesand entertainment during the three-day-long event.The Magic Future Square in the middle features all thekey note speakers, while the two smaller squares, Eastand West, will have more of a technical orientation,with shorter presentations running non-stop throug-hout the day.
Want to become a Magic Future Event Partner withthe possibility to influence what goes on at the squares?Exhibitors surrounding the Magic Future square willhave direct access to the event’s biggest meeting areawhich guarantees unique visibility and closeness tocustomers and activities. You will also be a part of the
conference committee as well as the project groupresponsible for square design. Visibility in the overallmarketing of the event is included. Slot-time is reservedfor you at the Magic Future Square and at either orboth of the smaller squares.
Exhibitors located elsewhere in the Hall have thepossibility of becoming Magic Future Event Partnersif they book a Magic Future Event Package.As Event Partner East/West you will have one of thesmaller squares next to your exhibiting space. Slot-timeis reserved for you at either or both squares.
We would like to invite all companies to take a moreactive role in maintaining the event SPCI the bestmeeting point in the global pulp & paper industry!
A Brand New Concept:The Magic Future of Pulp & Paper!
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The ExhibitorsSince the start back in 1968, thousands of companies have continuallychosen SPCI as the most important forum to meet customers and ex-changing know-how.
SPCI 2011 provides you with first class business opportunities inan international environment and is a great source of inspiration forexhibitors and visitors alike.
The world’s leading event in the pulp and paper industry guaranteesthat your products and services will get maximum exposure.
We welcome suppliers to the pulp, paper, board, tissue and con-verting industries to exhibit within all relevant product categories.
Thanks to the extended main hall at Stockholm International Fairs,the SPCI event will this time be concentrated to the one hall of atotal 30,000 sqm (320 000 square feet).
The world´s leading Pulp & Paper Event• 13 587 visitors from 61 countries• 730 exhibitors (450 of them from 32 differe• 293 exhibition stands
Book your stand bysubmitting your applicationtoday or make an on-linebooking at our websitewww.spcievent.com
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TheVisitorsAccording to our survey in 2008, executed by the Scandinavian SurveyGroup, an independent audit company, the visitors were unanimous;SPCI is considered the worlds leading event for the pulp and paperindustry.
• 34% of the visitors came from outside Sweden representing61 countries, making it the most international event of itskind worldwide.
• 64% of the visitors consider SPCI the leading pulp and papertrade show in the world
• 58% of the visitors had current purchasing needs and plannedto place an order within 12 months
• 62% of the visitors answered that they had major influenceover purchasing decisions
Since the first show back in 1968, SPCI gathers visitors from aroundthe globe.
You will meet a wide range of target groups at SPCI 2011, includingCEOs and mill managers from mill-wide operations, as well as speci-alists and managers in various sectors: Purchasing managers, Technicalmanagers, Production managers, Maintenance managers, Environmentmanagers, Marketing managers, Operators, Transport and logisticsmanagers etc.
The event will be extensively marketed to the pulp and paper in-dustry worldwide by organisers, agents, media partners, trade pressand co-operating partners.
nt
ifferent countries outside Sweden)
Official results SPCI 2008
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East or West Event Partner11-
· Presentation slots – one slot at West or East square (15 min + 5 min) per day
· Half page advertisement - Event Magazine/Guide
· Company logotype in Conference Programme and on event website
· Eurosize posters -signage – along the pedestrian walk from train station, by the Western entrance at parking areas
· DropPapers/Signage - At the venue when entering the exhibition hall
· Stand space marked with company logotype on all hall layout situation plans
· Wireless Internet access in stand
Price: SEK 49.000
For further information about these packages, please contact:
Marina Asp, CEO SPCI, + 46 8 783 84 [email protected]
Patrik Löwstedt, Exhibition Manager Adforum, + 46 8 749 43 [email protected]
Magic Future Event Partner
· Member of the International Conference Program Committee and the Conference Area Project Group
· Presentation slots – One slot at the Magic Future Square (25 min + 5 min), one slot at the West Square (15min + 5 min)and one slot at the East Square (15 min + 5 min) in total.
· Full page advertisement - Event Magazine/Guide
· Editorial coverage - Event Magazine/Guide
· Company logotype in all Magic Future Square marketing material; advertisements, newsletters, program etc.
· Possibility to buy a maximum of 20 tickets to the VIP-event atthe Vasa Museum on Wednesday May 18, 2011.
· 25 complimentary tickets to the City of Stockholm official reception in the City Hall on Tuesday May 17, 2011.
· Eurosize posters -signage – along the pedestrian walk from train station, by the West entrance and at parking areas
· DropPapers/Signage – by the East and West entrances
· DropPapers/Signage – At the venue when entering the exhibition hall
· Stand space marked with company logotype on all hall layout situation plans
· Wireless Internet access in stand
Price: SEK 198.000
“““
“Take this oppor-tunity to learnand network.Leadership abilityis crucial! Loo-king forward togive a presenta-tion on the sub-ject at the Magic-Paper roll.
Leif Brodén, CEO Södra
The new SPCIevent opens upfor new possibili-ties. The ideawith an openforum for confe-rence will movethe traditionalconcept with ex-
hibition and conference to a totallynew and fresh level.
Magnus Hall, CEO Holmen
The SPCI event isa very importantplace where wegather networkand technologyinformation.Jan JohanssonCEO SCA
The opennesshas always beengreat valued inour industry. Thenew SPCI forumwill walk the talkand Billerud willshare our newinnovations with you from theMagic square - so be there!Per Lindberg, CEO Billerud
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General InformationDates andVenueMay 17-19, 2011Stockholm International Fairs
Opening hoursTuesday – Thursday 09.00-17.00
Registration fee, Stand rental and Event partner packagesRegistration fee: SEK 4,500Stand rental: SEK 1,960/sqmEvent partner packages: Optional (see previous pages)VAT will be added when applicable
Exhibitor ServiceAll exhibitors are supplied with a special Service Kit with detailed informationand order forms for all available technical services.
Fair PromotionSPCI 2011 will be extensively promoted to buyers all over the world. Adverti-sements and international press contacts will promote the event. Membersof key national and international target groups will get personal invitations.
Contact InformationThe EventThe Swedish Association of Pulp and Paper Engineers (SPCI)Box 5515, SE-114 85 Stockholm, SwedenPhone: +46 8 783 84 00, Fax: +46 8 661 73 44www.spci.se
• Mrs Marina Asp, Executive DirectorPhone +46 8 783 84 [email protected]• Ms Camilla Sinivaara, Event ManagerPhone +46 8 783 82 [email protected]
The ExhibitionAdforum ABSE-125 80 Stockholm, SwedenPhone: +46 8 749 97 31, Fax. +46 8 749 35 05www.adforumworld.com• Mr Patrik Löwstedt, Exhibition ManagerPhone: +46 8 749 43 [email protected]• Mrs Kristin McKechnie, Exhibition Marketing CoordinatorPhone: + 46 8 749 97 [email protected] Helsinki office, Finland• Mr Marcus Bergström, SalesPhone: +358 9 150 [email protected]
International Representatives
Asia (except Greater China)
Mr Tan Kay Hui
Tel: +65 9790 6090
Fax: +65 6280 2823
E-mail: [email protected]
Germany, Austria and Switzerland
Mrs Annelie Bäck-Heuser
Bäck+Partner Marketing
Tel: +49-202-283 81 26
Fax: +49-202-283 81 27
E-mail: [email protected]
Greater China
Mrs Grace Mak
E.J. Krause & Associates, Inc. Beijing
Tel: +86 10 8451 1832
Fax: +86 10 8451 1829
E-mail: [email protected]
Italy
Mrs Carla Salaris
Lighthouse S.r.l.
Tel: +39 02 54189640
Fax: +39 02 54121746
E-mail: [email protected]
Spain/Portugal
Mr Eduardo Teixeira-Alves
Tel/fax: +34 96 3122197
E-mail: [email protected]
South America
Mrs Selma Regina Ugolini
go.va
Tel: +5511 2218-0005/0422
Mobile: +5511 9904-5350
E-mail: [email protected]
USA
Mr Björn Bieneck
Bieneck International
Tel: +1 (540) 372-9800
Fax: +1 (540) 372-1414
E-mail:
Visit our website atwww.spcievent.com
Organised by:The Swedish Association of Pulp and Paper Engineers (SPCI)AdforumStockholm International Fairs
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Improve yourbottom line!Your daily production problems are ourchallenge - get expert advice and tailor-madecomplete solutions from BTG.
Talk to the experts!
www.btg.com [email protected]