Western Michigan University ScholarWorks at WMU
Paper Engineering Senior Theses Chemical and Paper Engineering
4-1998
The Recycling of Vacuum Formed Products and the Effect on Use Characteristics
Robert J. Miles Western Michigan University
Follow this and additional works at: https://scholarworks.wmich.edu/engineer-senior-theses
Part of the Wood Science and Pulp, Paper Technology Commons
Recommended Citation Miles, Robert J., "The Recycling of Vacuum Formed Products and the Effect on Use Characteristics" (1998). Paper Engineering Senior Theses. 295. https://scholarworks.wmich.edu/engineer-senior-theses/295
This Dissertation/Thesis is brought to you for free and open access by the Chemical and Paper Engineering at ScholarWorks at WMU. It has been accepted for inclusion in Paper Engineering Senior Theses by an authorized administrator of ScholarWorks at WMU. For more information, please contact wmu- [email protected]. The Recycling of Vacuum Formed Products and the Effect on Use Characteristics
by
Robert J. Miles
A thesis submitted
in partial fulfillmentof
the course requirements for
The Bachelor of Science Degree
Western Michigan University
Kalamazoo, Michigan
April 20, 1998 Abstract
Vacuum formed products, commonly called molded pulp, are a superb alternative to expanded polystyrene (Styrofoam) in many current packaging applications. This movement from the petroleum based products of the past to innovative new wood fiber based packaging is due to many reasons including economic benefit, environmental stigma, and/or legislative intervention. The current dilemma is dealing with the inherent fiber characteristics, contaminants, and product composition of molded pulp products. As more of these products appear in secondary waste streams, there is a need for informationpertaining these parameters. Unfortunately, very little technical informationis available due to the high level of competition in this field.
Therefore, this project attempted to provide some of this background data by comparing several different samples of molded pulp to standard control samples of 0cc, ONP, and a forty two pound virgin kraftliner. The samples were analyzed on the basis of fiber length distribution, freeness, fines content, reject rate, repulpability, and recyclability. Results showed extensive variation, especially in the area of freeness and contaminants. Freeness data ranged from 300 ml to 710 ml depending on the sample type, while contaminants included ink particles, dirt, plastics, shives, stickies, and wax.
Based on this project it seems as though a wide variety of raw materials are used to produce vacuum formed products. Therefore, carefulscreening to ensure proper handling of these materials is advised.
Molded pulp is an excellent low cost fiber source forspecific applications where this high level of variation can be tolerate. Recycling results showed that both surface and strength properties of each sample performed within or near the results of the two control samples.
In summary, molded pulp provides an environmentally friendlyalternative to the plastic based packaging of the past. The results from this report show that these fibers could fitvery well into certain papermaking processes. There are many additional areas of research available in this fieldwhich will become more apparent as growth continues. If the movement fromEPS to molded pulp continues, it will be necessary to devote more research as a larger portion of this fiber stream needs to be recycled. Table of Contents
Abstract Table of contents Introduction 1 Theoretical and Background Discussion 3 Experimental 8 Results 12 Discussion of Results 20 Conclusions 32 Recommendations 34 Literature Cited 35 Appendices 36 Appendix I: 37 Appendix II: 38 Appendix III: 47 Appendix IV: 48 Appendix V: 51 I Introduction
In the paper industry there is a current trend toward using increased amounts of post
consumer waste in specific product lines. This is due, in part, to parameters such as legislation, public opinion, and customer demands. With this rapidly changing movement from virgin to secondary fiber there are inherent issues that must be dealt with. One of these topics is dealing with new products that may react differentlyto individual processes.
One relatively new product that has seen tremendous growth is the molded pulp industry. Molded pulp is any product that is formedunder a vacuum using pre-formed three dimensional screens. Due to the nature of production, both "molded pulp" and "vacuum formed products" refer to the same type material. Many types of raw material can be used in the production of molded pulp including old news print, old corrugated containers, mixed office waste, and many other materials depending on the end use requirements of the product and resources available. The focus of this project was on 100% wood based molded pulp products, although the opportunity exists for other raw material sources such as those
discussed below.
"A molding composition is provided foruse in forming a molded pulp alternative to PS foam in package cushioning materials. The composition comprises pulp fibers (e.g., slushed wastepaper); a plasticizer such as glycerol; a binder such as chitosan or an acrylic resin; and expandable plastic microspheres in an amount of S0
With this unique product comes additives, raw materials, and contaminants that must
be dealt with in order to ultimately reuse the fiber constituent. If steps are not taken to ensure
proper use of such streams, the results could be costly to paper mills. 2
This project attempts to provide this background data on typical fiber characteristics and runnability criteria for fiber sources derived from the manufacture of several selected vacuum formed products. The information contained in this report is intended for use in evaluating the impact of secondary fiberuse on paper mill operations and final product requirements. Most importantly, this project analyzes many key components as to fiber characteristics, typical composition, and how the material relates to equipment, flows, quality, and other important parameters in today's paper mill. 3
Theoretical and Back2round Discussion
Little work has been done in the area of repulping and recycling vacuum formed products. The progress that has been made is usually highly confidential and remains undisclosed. The molded pulp market has been controlled by relatively small, specialized companies that are trying to preserve their competitive edge.
To begin a discussion on vacuum formedproducts it is essential to get a feel for the steps involved in production. The actual process of creating molded pulp is best described in the following patent description:
"Molded pulp structures are provided to substitute forfoamed plastic structures in cushioning articles packed in outer containers. The pulp structure is molded to include an assembly of ribs, recesses and the like that absorb mechanical shocks and protect the packaged articles. Some elements in the structure break under acceleration at certain levels to provide the desired s h oc k resistance. . ,,2
Figure 1 may also be helpfulin understanding the basic concept of production.
Figure 13
....a-•..•0,4.. '
-~•--«--
=:::z- 4
Vacuum formedproducts have been used in significantly more applications in recent years. According to Friberg4, an annual growth rate of 20% can be anticipated. The most recent figures available indicate that present use, as of 1993, is approaching 500,000
tons/year. This supply comes form only 30 North American factories. Some uses for molded pulp since 1983 include: egg cartons, fruit trays, drink trays, wine bottle trays, produce packages, innerpacks, packaging corners/edges, electronics packaging, heavy industrial packaging, and pallets. With these examples in mind, it is easy to see that there is excellent growth into markets typically held by plastics and expanded polystyrenes(EPS).
Molded pulp is a superb alternativeto traditional materials in certain instances.
Packaging inserts are one area where plastics and stryofoam still control a large percentage of the market. This provides an excellent area for growth in the coming years. An example of the possibilities for molded pulp is shown in the following advertisement for "REFlexx"
fromMoulded Fibre Technology.
"Moulded Fiber Technology (MFT), a division ofUFP Technologies, is the leading designer and manufacturerof custom engineered packaging made from 100% recycled paper. MFT has successfully reinvented the principles of traditional moulded fibre, conventionally known as "egg carton" material, to create value-added custom packaging forconsumer electronics and computer peripherals. ReFlexx, MFT' s flagship product, has proven the value of 100% recycled moulded fiber packaging by successfully protecting products for Apple Computer, Motorola, Canon Virginia, Inc., US Robotics, Cabletron, Honeywell, Hayes Microcomputer, Ericsson GE, and others. To deliver the market the most sophisticated and highest quality moulded fiberpossible, MFT assembled an experienced team of moulded fibredesign engineers, moulded fibre tooling experts and moulded fibermanufacturing engineers. MFT' s vertical integration ensures that designs, tools and products will be escorted through the moulded fibre process and made to exact performance specifications by the most talented people in the moulded fibre packaging 5 business. As your packaging partner, our team will show you how ReFlexx moulded fibrecan work for you. "5
Table 1 is a brief summary comparing the advantages of molded pulp with respect to petroleum derived products. There are two major environmental advantages. Vacuum formed products are touted as 100% recyclable and an excellent fuel source with many second generation applications. This is important in a highly competitive market considering
6 the rate for recycling of plastics is only 1 %, while paper is close to 20% .
Table 1-
Wood Based Products Petroleum Based Products
Production base Largely north American Mostly offshore Recycle rates Relatively high (30-50%) Very low Incineration use Excellent Poor Raw material sources Renewable on short term Renewable over long term Environmental residence time Short Medium-High Breakdown capability Biodegradable Low Energy required to recycle Low Medium-High Pollutants when incinerated Very small Heavy metals (Pb and Cd)
One product line that is growing substantially is flowerpots and seed containers. A company in Oregon, Western Pulp Products Company, has been using recycled newspaper and kraftpaper trimmings to manufacture these types of products. They are now marketing a system of planting "Pot-And-All" where the seedlings' container is leftin the ground upon planting. In a recent advertisement, it was stated that "Horiculturally, our ability to biodegrade is a valuable benefit because Western containers can be planted "pot-and-all". By 6
doing so, delicate roots are not disturbed, transplant losses are reduced, and the Environment is left undamaged." This is one more instance were molded pulp has founda niche.
The current "environmental movement" has prompted companies to search for more
"friendly" alternativesfor various packaging materials. Vacuum formedproducts has filled this requirement in a number of cases. It also has some advantages over traditional packaging in some instances. For example, molded pulp typically has a higher absorbency capability when transporting liquids. A company that recently made the switch fromthe traditional two thermoformedPS tray innerpack to a molded pulp alternative was Johnson and Johnson. By making this switch in their "One-Touch II" blood-glucose home testing kits, they not only displayed "greener" packaging to their consumers but also discovered packaging savings due to both a cheaper raw material and an overall smaller packaging size.8
A picture of this product can be found in Appendix I.
The health and human services industry also has several other applications where
wood based products excel due to the need for repeated sterilization and "throw-away'� packaging to their incinerators. The one drawback that fiberbased packaging has is a low
resistance to deformation upon impact. This limits the use in application such as high end
electronics, equipment, and other high value markets.
Depending on the requirements of the container, a number of different furnishes may
be used during manufacturing, which was proven through this project and will be discussed
later. In applications where high strength is required such as internal packaging of heavy
industrial equipment, an OCC based fiber can be used. For other applications, ONP or mixed 7 officewaste may be used, lending the added dimension of versatility. Many molds can be used with a wide variety of furnishes, leading to lowered cost with respect to raw materials.
The goal of this thesis was to gain a better understanding of the variables involved with molded pulp products and their application. With this knowledge it was possible to investigate inherent properties of secondary paper products made with these fibersand also provide some baseline data on typical fiber characteristics used in the manufactureof molded pulp. Knowledgeof this data could provide an added edge to recycling mills in the papermaking and environmental arenas.
To attain this goal it was necessary to develop a procedure that " ...establishes a repeatable laboratory method for simulating mill repulping and recycling. It is intended for use in evaluating the impact ofrepulping and recycling (molded pulp products) on mill operations and final products."9 8
Experimental
The first step in determining the previously mentioned information is to define the methods that will be used. Presently there is a proposed IPST testing format, AFPA guidelines fortesting, and several TAPPi methods available for this application. Relevant portions of each were extracted and used to differingdegrees throughout this work.
Appendix II contains each of the methods that are referred to in the report.
To test a representative sample of what is currently available, a large sample of several types of molded pulp products were collected. A wide variety of samples were collected covering a broad spectrum of end use applications. This included each of the samples foundin Table 2. A list of the actual designations of each pulp and comparative samples can be foundin Appendix III. 9
Table 2
Molded Pulp Samples Collected for Thesis Project
Description Application(s)
1. Laserjet printer toner Provide stable packaging fortoner cartridge innerpack during transit
2. Lightbulb tray (several sizes, Trays found between layers of fluorescent raw materials, sizes, etc .. ) lightbulbs to avoid damage that may occur from contact with one another
3. Drink tray (several styles) Used primarily in fast food restaurants to hold several containers during customer transport
4. Egg carton The most recognized application, to package eggs forcustomer use
5. Pump top packaging Innerpack used with pump to provide stability during transport, fills up empty space to reduce shifting
6. Vacuum cleaner innerpack Innerpack used with vacuum to provide stability during transport
7. Industrial pallet (several types) Alternativeto typical wood pallets, numerous advantages
8. Fruit trays Tray used during shipment of, and to display produce in supermarkets
9. Television set innerpack Provide stability during transport to avoid shiftingwithin external packaging material
10. Flowerpot Provide container for plants and may incorporate nutrients to promote growth 10
The actual baseline evaluation of these various products was divided into two initial parts. The first component encompassed repulpability or the ability to repulp each sample under standard conditions. Also included in the repulpability portion of this project was typical pulp testing including ash content and freeness. The second portion of the experiment dealt with recycling of the resulting pulps into handsheets and evaluating certain parameters.
The procedure for each of these sections are given below.
Repulpability
1. Obtain a representative sample of the molded pulp to be evaluated. From this sample select a small portion and determine the moisture content according to TAPPI T 412. From this data, select 24 grams of oven dry sample to test. Selection should be "clean" but also representative as possible of the material as a whole.
2. Tear the selected pieces into approximately one square inch pieces. Place this sample into a T APPi (British) disintegrator and add two liters of deionized water at 70 degrees Fahrenheit.
3. Measure and record the pH of the mixture. Repulp for50,000 revolutions and measure the ending pH and temperature. This information should also be recorded for future reference.
4. Performa visual inspection of the repulping vessel and rotor for any contaminant or wax deposition on walls or rotor. Note any deposits accordingly.
5. Use half (approximately 1000 ml) to forma 12" x 12" to a target basis weight of 32 lb/1000 ft2 handsheet for futurevisual inspection. Performa fiberclassification on a Clarke classifierapparatus according to TAPPI T 233 cm-95. Calculate average fiber length and percent rejects from this evaluation.
6. Obtain another 24 grams oven dry fiber and disperse according to steps 1-4. Perform, in triplicate, a Canadian standard freenesstest according to TAPPi T 227 om-94. Correct for consistency and temperature and record the results for futurereference.
7. Obtain 1.5 grams of oven dry material and determine ash content according to TAPPI T 413 om-93. Calculate and record the results for futureanalysis.
8. Perform steps 1 through 5 for each of the samples collected. 11 Recyclability
1. Obtain a sample of the molded pulp to be evaluated. Performa moisture content analysis according to TAPPI T 412 om-94.
2. Tear the selected material into approximately one square inch pieces.
3. Place 24 grams oven dry sample into the disintegrator and add two liters of deionized water at 70 degrees Fahrenheit.
4. Disperse the solution for 50,000 revolutions and dump the resulting slurry into a sample bucket forlater use.
5. Repeat steps 2 through 4 eleven times to produce 21,000 ml of 1.2% consistency stock. Add each pulp to the previous in the bucket. Afterthe bucket has been filled, place a tight fitting lid on and store in a refrigeratoruntil handhseets can be made.
6. Repeat steps 1 through 5 for each of the samples to be examined.
7. Handsheets were made on the Noble and Wood apparatus without finesrecycle. A 2 basis weight target of 42 lb/1000 ft was used for each set. Sheets were pressed through one nip using fivepounds on each arm of the press foundin the wet lab. The sheets were dried using the standard dryer can also foundin the wet lab. Fifteen sheets were produced, and the best ten, upon visual inspection, were used fortesting.
8. Condition handsheets for at least 24 hours in a standard 73 degree Fahrenheit and 50% humidity environment.
9. Test handsheets for basis weight, caliper, porosity, smoothness, tensile, mullen, and opacity. The method used for each of these tests can be foundin Table 3. Each of the actual test procedures can be foundin Appendix II. 12
Results
The repulpability portion ofthis project yielded data for freeness, reject rate, percent fines, average fiber length, and ash content. A visual inspection was also done on each of the samples prior to and during pulping. Each of these parameters will be discussed. The recyclabiliy portion ofthis project yielded data forpaper tests including basis weight, caliper, density, opacity, mullen, tensile, Scott bond, and smoothness. Again, each ofthese results will be discussed in furtherdetail.
The ash content for the molded pulp samples ranged from 1.85% to 14.2%. This is in comparison to random newsprint, liner, and OCC samples of .8%, .7%, and 1.4% respectively. Actual sample data for each group can be seen in Figure 2, on page 13.
The Clarke Classification procedure provided insight as to reject rate, finescontent, and average fiber length. For the purpose of this project, the portion of each sample that did not pass through the initial # 14 screen was considered rejects. A close visual inspection showed that this was appropriate. Also, forthe purpose ofthis project, the portion ofeach sample that was able to pass through the final#100 screen was considered fines. By subtracting the dry weight of the material entering the system and the total weight ofmaterial caught after each screen, the difference was the material that passed the finalscreen.
The reject rates formolded pulp samples ranged from.2% to a high of29.2%. The unusually high reject rates will be examined more closely in the discussion section of this report. Baseline sets of ONP, OCC, and kraftliner resulted in reject rates of 4.7%, 7. 7%, and Figure 2 Ash Content of Molded Pulp Sam pies
42# liner sample Old Newsprint Old corrugated containers Flower pot Lightbulb innerpack l I GI Lightbulb tray (medium)� :o Lightbulb tray (large) t Fruit Tray Egg carton Fast food drink tray Lightbulb tray (medium) Pallet (waxed)
-- -,...� ---_------_- _...i - - _- - _- - _- _- _- _...i_- _- _- _- _- _- _- - - _...J - - - _- - - - _- _- -�_- ...,.,-. Lightbulb tray (small) ------Printer toner innerpack ======---======-=--=--=--=--=--=--- - , t ..,, WM , 0L Pump top case _ ,_, ,, _, ,._;_, . :_ _ , ·, : .,. __ ,, .: •· .! , ,__ j tf I I I I -I Pallet (unwaxed) ~'I I I I I I • Steam cleaner innerpack _,,, I I I I • Television innerpack ,, I • 1 _ : � ., ---s ·- · ·1,---. 1 < · 1 2 · ·• ·.; • :::::..::n • , ----' ·, , ; • - . := .. : . Steam cleaner innerpack 1 • -· -- · • -�· -· 0 2 4 6 8 10 12 14 Ash Content(%) 14
1.7% respectively. A more in depth characterization of the type ofrejects that were found will also take place in the discussion section.
Fines comprised between .8% and 41.4% ofeach sample. Average fiber length, as computed using the Clarke Classification data ranged from .26 mm to .98 mm. A summary of each ofthe previously mentioned properties can be foundin Table 3. Appendix IV contains the raw data forthis section ofthe report.
Table 3
Sample Reject Rate(%) Fines (%) Average Fiber Length (mm)
Laserjet toner innerpack 5.4 8.6 .57 Lightbulb tray (medium) 0.2 41.4 .26 Fast food drink tray 0.3 29.2 .38 Egg carton 0.7 25.8 .42 Pump top casing 1.9 21.7 .41 Lightbulb tray (large) 0.3 24.4 .40 Lightbulb tray (medium) 0.4 27.8 .39 Lightbulb tray (medium) 1.4 23.3 .41 Pallet (unwaxed) 0.1 24.7 .39 Old newsprint 4.7 10.3 .53 Old corrugated containers 7.7 8.6 .62 42# liner sample 1.7 10.4 .53 Lightbulb innerpack 0.3 25.4 .40 Television innerpack 5.2 22.3 .47 Pressure cleaner innerpack 7.0 16.5 .54 Small cleaner innerpack 3.9 21.0 .47 Fruit tray 29.2 0.8 .98 Pallet (waxed) 13.5 12.7 .66 Flower pot 4.4 13.3 .48 15
The one remaining repulping test that was performed was freeness. Each sample was repulped according to the previously mentioned procedure with freeness tests performedin triplicate. The values and average of these three freenesstests foreach sample is given in
Table 4. The data is also shown in graphical formin Figur� 3, on page 16.
Table 4
Freeness 1 Freeness 2 Freeness 3 Average Sample Identification (ml) (ml) (ml) (ml)
Laserjet toner innerpack 678 643 654 658 Lightbulb tray (medium) 452 432 519 468 Fast food drink tray 335 355 353 348 Egg carton 351 339 334 341 Pump top casing 445 486 432 454 Lightbulb tray (large) 526 569 515 537 Lightbulb tray (medium) 385 443 430 419 Lightbulb tray (medium) 673 670 672 672 Pallet (unwaxed) 613 616 601 610 Old newsprint 288 288 342 306 Old corrugated containers 735 720 699 718 42# liner sample 721 703 721 715 Lightbulb innerpack 449 407 426 427 Television innerpack 545 546 561 551 Pressure cleaner innerpack 614 598 634 615 Small cleaner innerpack 543 664 523 577 Fruit tray 685 734 740 720 Pallet (waxed) 670 622 670 654 Flower pot 731 696 741 723
The recyclability portion of this project was performed on fivedistinct sets of molded
pulp types. Initially, the end use application was to determine the sets such as consumer use, Figure 3 Freeness Values for Molded Pulp Project
21
2
19
18
17 :: �§�������i�������� 14
13
012 z !11 E 1 ===J======L � ���;;�=====!::== :8 i���;���������� 7
6
5
4
3
2
�-· ...... i �"'~ ��.�-:.-,.,,_, I 0 10 20 � 4 5 6 70 8 CSF (ml) 17 industrial, etc .. None of the repulpability data agreed with this classification, however, and many other classificationswere looked into. The actual separations ended up being based on visual differences. From the freeness values presented in Figure 3, it was noted that the color of each sample varied proportionally with the level of freeness. Figure 4, on page 18, shows the relationship between the apparent fibertype in each sample and freenessvalues fromthe repulping section.
The recycling of molded pulp products and subsequent sheet formation is the topic of
the next portion of this discussion. The fourgroups of fibertypes fromFigure 4 with an additional run forthe unwaxed pallet sample was performed. The 42# liner sample that the
baseline repulping information was extracted fromwas also included in testing. This is for informational purposes only for comparisonand will not be discussed at any length.
Each of the handsheets were within fivepercent of the target basis weight of 42 lb /
2 1000 ft . Appendix V contains all the raw data from handsheet testing. To summarize the
results of handsheets testing, caliper values were between a low of 17 .1 mils, forthe pallet,
and a high value of 21.8 mils forthe gray group. Opacity values ranged from28.8 % to 45 .3
% and smoothness was around 9.5 microns to 10.5 microns for all sets. The gray samples
3 resulted in the lowest average density at 24.6 lb/ft , while the pallet sample resulted in a high
3 average density of 30.8 lb/ft .
Strength testing was also performed in the form of tensile, mullen, and scott bond
analysis. Tensile values forthe ranged from 30.7 lb/in. to 53.3 lb/in. forthe light brown and
gray groups respectively. Mullen testing resulted in the same relationship with the gray
group at the high end with a value of 55.5 psi, but the pallet designation was -QO Figure 4 Freeness Values for Molded Pulp Project 800 .�_.�.-,__ _ __ . ___ . __ . __ _ __ ,._. _
700 - -e 600 w G) i 500 ! LL. "CJ ; 400 "CJ C c
C 300 c :sca C c 0 200
100 Gray White Light! Brown I Brpwn I . · I I 0 I I 0 2 4 6 8 10 12 14 16 18 Sample No. 19 lowest of the sets with an average force of 33.1 psi. The final test that was performedwas scott bond. Values for this test ranged from .03 ft*lbto .09 ft*lb. The molded pulp sample with the lowest average scott bond was the brown grouping and the highest average values were obtained fromthe white classification. 20
Discussion of Results
The first topic of discussion are the results of an initial visual inspection done on each of the samples. Visual analysis revealed several interesting factsboth beforepulping and after handsheet formation. Table 5 was used to provide most of this informationin an organized manner. The appearance of the sample refersto the type of fiberthat makes up the product. For instance, the egg cartons that were used for this project resembled the color of typical newspaper gray which is composed of heavily recycled groundwood. The waxed pallet, however, was a dark brown color identical to the kraftliner sample that was also used.
Some of the typical contaminants that were found include plastic, shives, wax, and fiber
bundles. Also found were sticks, straw, and many other various odds and ends usually on the innerplys of some of the thicker pieces.
Table 5
Visual Analysis of Pulp Samples
Finish Sample Description Appearance Vacuum Side Screen Side Contaminants
Fast fooddrink tray Groundwood Smooth Medium Some kraftand bleached undispersed fiber bundles
Egg carton Groundwood Smooth Smooth Very fewbleached specs very few dyed fibers
Old news print Groundwood NA NA High level of ink particles
Laserjet toner innerpack Bleached fiber Smooth Medium Some ink particles
Small lightbulb tray Bleached fiber Smooth Medium Fiber bundles, stickies, ink particles, and kraftshives all present in differingdegrees
Medium lightbulb tray Bleached fiber Smooth Rough Slight ink, some stickies, numerous kraftfibers/shives 21
Large lightbulb tray Bleached/kraft Smooth Smooth Few small plastic pieces, several colored plastic fibers
Pump top case Light kraft Smooth Rough Few bleached undispersed fiberbundles, some wax, stickies, foil, ink, and dirt
Pallet (unwaxed) Light kraft Rough Rough Very heavy plastics in inner plys, wax particles, numerous sbives, and a fewdyed specs
Television set innerpack Light kraft Smooth Rough Numerous stickies and shives, some ink flecksand dirt
Steam cleaner innerpack Light kraft Smooth Rough Few large stickies, ink particles, and undefinedblack specs
Small cleaner innerpack Light kraft Smooth Rough Few large plastic pieces, numerous shives, some ink particles
Medium lightbulb tray Kraft Smooth Smooth Many undispersed fiber bundles, some stickies, numerous hives
Old corrugated containers Kraft NA NA Some dirt and shives
42# liner baseline sample Kraft NA NA Very little shives and dirt
Pallet (waxed) Kraft Rough Rough Heavy wax coating, large amount of ink, shives, stickies, and bleached fiberbundles
Fruit Tray Purple dye Smooth Medium Purple color, fewkraft sbives
Flower pot Peat material Coarse Coarse Made frompeat material, large amounts of bark, sticks, dirt, and white specs
Ash contents were unexpectedly low. All samples were below 15%, which was seen in Figure 2. The companies that were contacted forthis report had stated the possibility of using paper mill sludge and many other non-typical raw materials to produce molded pulp. 22
It was expected that some of the samples may have ash contents as high as 25%-50%. This would indicated the presence of fillersand contaminants such as dirt, metals, and other inorganic material. The ash content might also include:
" .. various residues fromchemicals used in its (the products') manufacture, metallic matter from piping and machinery, mineral matter in the pulp fromwhich the paper was made, and filling, coating, pigmenting and/or other added materials." 10
From Figure 2 it is also apparent that all fiveof the light brown samples had similar ash contents from10% to 14%. These were also the highest ash contents of any of the samples tested. Some possible explanations for this include manufacturer, fibertype, and manufacturing method. The most probable explanation is that each of these samples were made by the same producer, using a standard furnish. It is difficultto know forsure however, due to the aforementioned high competition level.
Each of the baseline samples were relatively "clean". It would be interesting to classifythe inorganic fractionof the molded pulp samples. The type of material could give some indication of the place of origin, manufacturingprocess, and raw materials used.
Freeness testing is the next area of discussion. Figure 3, on page 16, shows the variation in samples from 300 ml to 700 ml. This was the most important breakthrough for this project. Afterdevising several ways to group samples for recycling, it was apparent that there was little correlation with any of the methods.
Upon visual inspection it was obvious that there was a correlation of freenessto color of the sample and vice versa. The three gray samples each had the lowest freenessvalues from 300 ml to 350 ml. The four white samples were proportionally higher between 410 ml 23 and 520 ml. The fourlight brown samples that were tested resulted in freenessvalues from
540 ml to 610 ml and the highest drainage numbers resulted from the brown group where all samples were above 650 ml.
The freeness test is a relationship to the rate at which a slurry of wood pulp may be drained. According to TAPPi standards, the freeness of a pulp has also been shown to be related to the surfaceconditions and swelling of the fibers. For more information on standard freeness testing referto Appendix II, at the end of this report.
The wide variation in freenessvalues may give an indication as to the vast differences in fibersused in the production of molded pulp. From the literature that was examined for this project it is evident that fibersources include old news print, old corrugated containers, and paper mill sludge. This would explain the tremendous freenessvariation and the distinct color differences.
Once it was discovered that the color / freenessrelationship existed, groundwood indicator, in the form of phloroglucinol, was used to try and get a feelfor the pulping methods that took place. The gray colored material that behaved similarly to the old newsprint samples were in factvery positive, upon visual inspection, for groundwood indicator. Proportionally less color indication resulted fromthe remainder of the samples. It is important to note however, that there was a distinct drop in the strength of the indicator solution when proceeding to differentcolored groups. This would indicate that differing pulps were used, which supports the earlier hypothesis that fourdifferent types of pulping methods were evident in the molded pulp samples. The most notable results were that the 24 control sample of old news print and virgin kraftliner acted similarly to others of the same color. This would indicate that a similar raw material was used.
The reject rates foreach of the samples is shown graphically in Figure 5, on page 25.
The most notable, and expected, result is the differencebetween the colored groups of samples. The brown and light brown samples have significantly higher level of contaminants in comparison to the white and gray samples. Only one kraft sample, the unwaxed pallet, contained less than 1 % rejects. All of the groundwood and bleached samples were below
1%.
The visual inspection that was summarized in Table 5 gave a good indication as to the type and quantity of contaminants that were present. The majority of the rejects were wax, plastic, ink particles, undispersed fiberbundles, and shives. One possible reason that the kraft samples were higher is that they were thicker on average and contained a high level of plastics on the inner plys whereas the thinner bleached and gray products did not have any room to hide such rejects. Also, the pallet that was waxed had a significantlevel of contaminants because no tertiary steps were taken to remove the wax particles fromsolution.
The average fiberlength of the samples were between .25 mm and .65 mm. The distribution of average fiberlengths is given in Figure 6 on page 26 foreach of the sample groups. It was expected that the kraftand light kraftsamples would contain longer fiberson average, due to the raw materials used. It was also expected that the white and gray groups would contain significantly shorter fibers due to the raw materials and freeness values from Figure 5 Reject Rate of Molded Pulp Samples
Waxed pallet I
Flower pot
Small cleaner innerpack ...... "'-----r-----.-a.
Pump top case
Medium lightbulb tray
Egg carton
Medium lightbulb tray
F astfood drink tray
Laserjet innerpack
Large lightbulb tray
Lightbulb innerpack
Small lightbulb tray
U nwaxed pal let ~ ==-=-=-=·-=-=-=--=-t··= -·=--=·--=-===-==+~--===-=-·-=-=-==--...:..=~======,z=:===-==--=-=---r-=------·--_·-- _-----~'"7'_--_--_--_-_-_·------, 0.0 2.0 4.0 6.0 8.0 10.0 12.0 14.0
Reject Rate(%) Figure 6
\0 Average Fiber Length of Molded Pulp Samples M
.,. Waxed pallet . . , . ' Steam cleaner innerpack
Laserjet innerpack
Flower pot
Small cleaner innerpack
Television innerpack
Egg carton
Medium lightbulb tray
Pump top case
Lightbulb innerpack
Large lightbulb tray
Unwaxed pallet
Medium lightbulb tray
Fastfood drink tray I i Small lightbulb tray i L =,,::= ;e= .. ) ) ------•-----+---·------· ------;J l 0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 Fiber Length (mm) 27 earlier testing. There was little correlation however, when looking at the average fiber lengths that were calculated from the Clarke classification results. In hindsight, a more accurate test method would have been to use a Kajaani fiber length classifierto determine fiber length distributions and a six cut screen to determine rejects.
The low freeness pulps that were used for the gray and white groups would tend to have a higher level offines, especially ifthey were highly recycled raw materials such as newsprint. Figure 7, on page 28, backs up this hypothesis with all but one ofthe gray and white groups containing the highest amount offines. Values ranged from3% to 5% for the gray and white samples while the brown and light brown samples ranged from 1.5%to 3%.
These fines contents were also based on Clarke classifierresults with an initial starting dry weight of8.5 grams of pulp.
Originally the recycling portion of this project was to be performed by differing the percentage ofmolded pulp slurry in a standard liner pulp. Due to lack oftime, however, five groups ofmolded pulp were dispersed and formed into handsheets forcomparison against two standards. The two baseline samples were a old newsprint and virgin kraftliner sample.
The results ofsurface and handsheet characteristics can be found in Figure 8, on page 29.
The caliper values for the three molded pulp samples were between 17 mils and 20 mils. These groups were slightly lower than the two control groups which were 21 and 22 mils forthe kraft and old newsprint respectively. Since each of the groups were
approximately the same basis weight, the density results showed the inverse relationship,
with the molded pulp samples slightly higher. Figure 7
Q0 Fines Content of Molded Pulp Samples N
Small lightbulb tray 'lnj
Fastfood drink tray X k.. '., �-�
Medium lightbulb tray
Egg carton -J I I I I I � Lightbulb innerpack •
Unwaxed pallet
Large lightbulb tray
Medium lightbulb tray
Television innerpack
Pump top case
Small cleaner innerpack
Steam cleaner innerpack
Flower pot
Waxed pallet
Laserjet innerpack --�.... ,,..______., __ .. .., . .-..,,..,__, .,.,__,,..�-- ---�- .... �.,.. 0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 Fines (grams) 0\ N Figure 9 Stength Properies of Handsheets Comparison of Caliper Values Comparison of Density Values
--··-1 -·--•·-·---�------, .._..,., ___ , � 25 · I _____ 35 30V! � 20 M° � 25 §.... 15 ::::.. 20 10 � 15 l 101/11 iv 5. ,,. � u QI 5 0 .i,,-i:a:::i~ 'i"""i--1'"'-"1£l...JE...-.i----1&"'1-....J C O 1..i:r•:gf'/1'1 i,::�;n Eli-"'" W',"� 0 >- - C: 0 C: 0 >- _c: 0 C: ('O .c: � ,:. I � .c:� .:. .:.c: I .... -=,ra , � 0 - �e § - e .S!> e § - e (.) C) co (.) co (.)g -C) ...... I co (.) co Sample ID Sample ID
Comparison of Opacity Values Comparison of Smoothness Values ·-··-· -·-- ---··-· ---·-- -·-··•·-·--- -··------·- 11 50 45 · ' VI 10.5 40 VI - - QI VI � 35 C C 10 30 .c 0... .� 25 -0 CJ CJ o ·E 9.5 "' 20 Q, 15 _,,, 0 u,E- 9 10 5 8.5 (I) C: - o~ ~~
Smoothness values ranged from 9.4 microns to 10.9 microns. The three molded pulp samples were well within the extreme values resulting fromthe control groups. Molded pulp smoothness values were from9.7 microns to 10.5 microns.
The strength testing was also indicative of the raw materials with each of the molded pulp groups strength values within the envelope created by the control samples. Page 31 contains Figure 9 which is the results of the strength testing for mullen, tensile, and scott bond. 31
Mullen (lb/in2) 60 20 40 50 30 10 0- 0 0 Control 3 -Gray "Cm :::::!. tA White 0 :::J en 0 Al 3 Light __ __.__--.. """ "C 3: � Brown C: Scott Bond ((ft"'lb)"' i5 co :::J 10"-3 Pallet Comparison ~-·• 60 20 40 80 50 30 90 70 10 < u, o, o,
.. m -· - / C: S' Control :::J Control - ��� ---·-·-, CD cc - Brown tA r+ Gray �
"'tJro ------
of "C White CD -"Tl•
Scott �cc en CD-· -, C: Al tA 3 Light CD "C �------10 � � Brown Bond """ :::c: i5 m :::J ------~ C.
Pallet Values tA Tensile (lb/in) � CD 60 20 40 50 30 10 0 0 0 Control � Brown 3 Control �����-..io· "Cm - Gray ::::!. -•�·• -· , tA __ 0 :::J en 0 Al """ 3 Light 1"-,!-----'-...... ,. --f "C CD � Brown :::J i5 tA Pallet CD- m< Control C: - Brown CD tA 32
Conclusions
Molded pulp products are made froma wide variety of raw materials. This has many implications when considering use of such products as a secondary fiber stream. The resulting freeness, reject rate, average fiber length, and finescontent all play a large role in making quality products. The variation from 300 ml to 700 ml in freeness, ash contents from
. 7% to 14.2 % and fiber lengths of .25 mm to .65 mm all show this. The runnability of paper mill equipment when using molded pulp products is related to knowledge of the fiber source and subsequent papermaking parameters. It is important to know how a particular raw material will behave in a given system.
Producers of molded pulp products also have to be aware of the recycling of their product that may take place and the issues that surround recycling. When a wax is applied to pallets to improve durability, the 100% recyclable slogan has to be taken with a grain of salt.
Careful screening needs to be done at secondary fiberpaper mills to ensure that the raw material that is being purchased is compatible with their individual processes. When contaminants such as wax, plastic, shives, fiber bundles, and ink particles are discovered it shows the importance of this screening of fiber sources.
The methods used to evaluate such materials should include some of the basic principles used in this project. Evaluation of molded pulp samples worked well and should be used in some form whenever possible when devising such methods. This will become more apparent as the movement fromEPS to molded pulp continues. It may also be 33 necessary to devote more research as a larger portion of this fiber streams needs to be recycled.
The recycling portion of this project showed that the surfaceand strength properties of sheets created using molded pulp were very compatible with the baseline old newsprint and virgin kraftliner samples. The strength properties including mullen, tensile, and scott bond were each evidence that molded pulp probably contains fibers characteristic to each process.
In summary, molded pulp provides an environmentally friendlyalternative to the expanded polystyrene of the past. The results fromthis report show that these fiberscould very well fit into certain papermaking processes. There are many additional areas of research available in this field, which will become more apparent as growth continues. 34
Recommendations
Further work may be needed in the futureto look at specific molded pulp products as growth increases. Many topics were discovered throughout this project including the effect of recycling, contaminant characteristic and level, and modernproduction processes. One topic that is currently being investigated is the use of paper mill sludge as a fiber source for molded fiber products. According to the literature cited for this project, this is possible, however there is no specific processes that are currently in use. 35
Literature Cited
Noguchi, T. Pulp Molding. Sony Corporation, Patent record number 379262, United States Patent Office, November 1, 1994.
2 Baker R.J., Noel M.P., McCullough, B.C. Molded-Pulp-Fiber Interior Package-Cushioning Structures, Moulded Fibre Technology Inc., Patent record number 376390, United States Patent Office, August 9, 1994.
3 Spangenberg, R.J, Secondary Fiber Recycling. TAPPI PRESS, Atlanta GA, 1993, page 71.
4 Spangenberg, R.J. Secondary Fiber Recycling, TAPPI PRESS, Atlanta GA, 1993, page 72.
5 Advertisement ReFlexx: Custom Engineered 100% Recycled Packaging. UFP Technologies, Georgetown MA, 1995.
6 Paddock, T. Banning Plastic is Not a Solution to Our Solid Waste Problems, Academy of Natural Sciences, www.acnatsci.org/erd/ea/plastic.2.html, 1996.
7 Carl, C. Paper or Plastic, Willamette Industries Executive Offices, Portland OR, 1996.
8 Demetrakakes, P. Medical-Device Packaging Must Fit The Prescription, PACKAGING, Volume No. 4, April 1994, page 22-24.
9 AFPA/FBA Voluntary Standard forRepulping and Recycling Treated Corrugated Fiberboard, Purpose Section, August 1996, page 2.
IO Technical Committee of TAPPi Ash in wood. paper andpaperboard: combustion at 900 C, TAPPI TEST METHODS - 1995, TAPPI PRESS, Atlanta GA, 1993, T413 om-93, page 1-3. 36 Appendices
Appendix I UFP Technologies
Appendix II Test Procedures
Appendix III Sample List
Appendix IV Clarke Classification
Appendix V Raw Data 37
Appendix I
\ I
con•umer el ectron,cs-· . . -,r Reh ..e. ,v.. l=- roteeUng the industry Wlt7l 1~ recycleo pe,per
Moulded Fibre Technology (MFT), adivision of UFP To deliver the market the mostsophi sticated and Technologies, is the leading designer aod D'.Wlufacturcr of highest quality mouldedfibre possible, MFT assembled ao custom engineered ptck.aging made from 10% recycled experienced team of moulded fibredesign engineers, paper. MFT has successfully reinvented the principles of moulded fibre tooling experts and moulded fibre manufac traditional moulded fibre, conventionally known as • egg turing engineers. MFT s venial integration ensures that canon• material, to createvalue-added custom packaging designs, toolsand products will beesconedthrough the for consumer dectronics and computer peripherals. moulded fibre process madeand to exactperformance RE.F'LF.xx, MFT'sBagship product, has proven the value of spccificstions by the most wcntcd people in the moulded 10% recycled mouldedfibre packagingby successfully fibre packagingbusiness. As your packaging partner, protectingproducts for Appl� Computer, Motorola, Canon our team willshow you bow REFI..Exxmoulded fibre Cl1ll Virginia, Inc., US Robotics, Cabletron, Honeywell, Hayes work for you. Microcomputer, EricssonGE, aod others. 38 Appendix II
Procedures Used for ProjectWork
Enclosed is each of the procedures used during the completi_on of this project. As is stated in the Literature Cited portion of this report, all methods used were taken from TAPPi TEST METHODS from 1994-1995 or relevant AFPA/FBA guidelines.
Test Performed Method Used
Ash content TAPPI T 413 om-93 Basis weight TAPPI T 410 om-93 Caliper TAPPI T 411 om-89 Conditioning of handsheets TAPPi T 402 om-93 Fiber classification TAPPI T 233 cm-95 Freeness TAPPI T 227 om-94 Moisture content TAPPI T 412 om-94 Mullen TAPPi T 403 om-91 Opacity TAPPI T 425 om-91 Porosity TAPPI T 547 pm-88 Smoothness TAPPI T 538 om-88 Tensile TAPPI T 494 om-88 11.' \ , AFPA/FBA Volunt:r Standard for Repulping and Recycling 39 Trc:tcd Corrugated Fiberboard
PREFACE
The disposal or" tre:ted c,)rgated b: grocery stores and othc rnc users can be a fnancial and \og1sucal burden W1k treated corgated containers ae the most practical and cost effective way to ship produce. meat. seafood and other items, cerain treatments have made recycling diffcult. It 1s desirable from both fber source and environental standpoints to encourage the development of treated corgated which may be rec\. ,ed using common mill techology. The corgated products industr• recognizes that the solution to this problem should be indust-wide. prmaly because corgated treated by a paicula compay with a cerain treatment caot be efectively identifed at the mills which recycle corgated. Different treatment systems may have d�ferent impacts pn recycling processes. ., and ?9fC have been considered highly detrmental ·by mill operators. Therefre, i�ped�rents to widespread· acceptace of new ad rore recyclable treatme'nt by the end users and the customers of the corgated indust remain. Several industry compaies offered to share their reseach in conection with recyclable treatments for corgated boxes. a well a data on repulpability ad the like. These compaies believed they had developd suitable forulations fr the vaous treatment applicati_on tech1qu�s used in _corgated box plat. ad were willing to publicly discuss tis�infonation �!th othe_rSrWthin te mduStJ' to achieve an exp· edited so�ution to the traditional dpe�_ ma_of . ·"
non-recvciabilitv� oi mav teated boxes � ••• - 4 •
·- To detemune 1nteres: in ths mane!. a infrational meeung wa held for industry · maketin ad tech1cai representatives The nature of te tndusty iro_bier ��- discu�s�d in .. ge�eral _ter�. ad te conscsus of tr.e groui wa that a incustr s01u11or would be aqprgpnate · ' · ad de�1 rable ·
Tc address ad ev ai.te the techrncai a well a the educational ad maketing 1pects of tis obJecttve. a Joint com1nee of te Fibre Pox Association ad the Amerca··Forest and Paper Assoc1a11on wa fored. Afe� nuerous meetings. nur..erous tests a.-: leg a: re\ 1ew, the· co.r.mee developed the araf. voiunta �'.uad for repulpaoi11ty ac �ecyclabiiit:, anached hereto. It 1s a non-product-spec1fc stadac. which creates a ne' grade of waste paper·. ; e , _:ne y which mee�· the stadad's repulpabtlity ad recyclabilit requirements ad which 1s marked· c: accordingly. While the prima impetus of this standad is in moisture trec,ments fr corugated. any . tre�tme! product fr ay purse that meets this stadard can be cer 1 fed.as rcptlpab_lc/r.ecyclable under the restrictions of this document.
.. - :- ...
. •-' ::. . ··- ·-~ i.. .. ~~--. :_-· ...... � t •• � ·-:... ••, .,.. . . . � ...... L. ,· ;· "':" .: -\, :· ~- ..... !·. , I',. I. - \ ·.~, I. rurpost 40 1.1 This standard establishes a repeatable laborator method fr s1mulat1ng a commonly used subset of repulping ad recycling processes. It 1s intended fr llSe in evaluating the impact of repulping ad recyclin! treated curu�atcd fbtrboard on cont:1nerb0Jrd mill opcrJt1ons Jnd fnal products
2 This standJrd estJbl1shes a proccss ior 1dent1 ring tre3ted corgated that can be re pulped ad recycled in this selected subset of processes It establishes minimum levels of perforance for the hadsheets made from treated corgated. repulped ad rec:cled in accordace with a detailed test protocol given 1r. Section 5 This stadard is not intended to preclude the development or use of ay technological advaces in mill or treatment processes It is intended to encourage the development. use ad repulping and recycling of treated corgated products. especially those fr use in high moisture environents.
' I ./ ' i 1 ', (_ 2. Scope . ' •~' ••I 2.1 This stadad applies repuiping, and recycling process, . te�hology·, i�_ef�ct-or rcadily . . ... - - . achievabie to mills cuently invol�ed.in recycling.
2.2 Tis stadad establishes a screening method fr deterining the repulpability and recyclability of souce sepaated treated corgated products that have n . 2 3 The test mef0� in this stadad ha two pas Pan l deterines the rtpulpabili�· of treated co'gated r:- deterining fber-on-foe� y,eld ·.·her. only te ;e:ne. .orJga,ed is processed in accor:a.e with this stadac (Appndix A) P-ar 1 deterines f1e rtc�clabili�· of the treated corgarec·o� evah.:afrng its effect on mil: c,;etat1ors ac i1n!she: pr: :uct. when 1t 1s ao.ed to un:�eated .vrugated in the aounts specified. (Appendix B) Tis voiuntary sta.dae does not re:ieve th� user from compli_ ace_ with all �pplicable local.. state ad federal laws. ad regulations and co·ntactual. ag'reeme;'ts. � . .. - . . -: . ;.. . . ·-· . . 2.5 This standard is not intended to addres.s the' fncti6nal:itv :or market��ili-tv of the. treated .. cprgated' ·, or �r rill products that use the treated co:rgated as a fber\oufce. : -~ . ' (' ,. ,; '; I•. t \ ,. I i 2 6 This stand.rd docs not :ddrcss :ll of the factors which should be considered in the development or a repulpablc and rccyclJblc treatment It ,s the re�ponsibility or 41 companies dcvclopins trcJtments and treated corugated and testing them under this stadard to make sure that. in addition to heing repulpable an- recyclable. the products will be safe and suitable to use for thc,r intended appl1cJt1on�. e g. fod contact pa.iag1ng. and that thev will not crc:Ht other non-des1rJbk �:, 1r, 0nmcntJI effects at tht point of use or disposal 2. 7 Treated corgated containers recovered fr rec:cling should not be contaminated by contents of the boxes. such a hadous or perishable materials 3. Defnitions of Key Terms: ntraction/extractable(s) - As pa of the test protocol. it is necessar to deterine the amout of treatment product present on the treated corgated ad 1n the accept from cerain processes. Since the treatment materals wll va· in nature. any approprate stadard process may .be used for this deterination. Such proess should be well recognized in the industr ad its use recorded on the cerifcation repr. As a exaple. TAPP� T405 may be used fr wax. . , ., Hereafer ..te general ter "exuction" wll be interreted. to mea the process.chosc��f.r"this . puose ad "extractable" is te sluble material that is. extracted in te procedue. . , .. fber on fber yield - is the aout of fber. which remains afer te processing actron. -xpressed as a per:entage ofthe fbr presnt 1n te materal to b tested. handsheets - ae sheets made from a suspensi<;m of fbers in wa_er in a operauon _:her�ly �ach sheet is fored septely b: drining the pllp susp�ns1on on a s�t1ona sheet mold. . - . OCC (Old Corgated Container, • 1� a grade of waste paper comprsed of untreated corgated boxes that have been ued for the puose for wh1ct. :ey were ong1n�;: purchaed, ad have subsequent!�· ben source sepaatec from other waste rec!·clable - usec ;ape=. including in-p1a,: ad pos; consume: was:e ?a:�: an. paperboad. which 1s :apable of being processed intc :ev paper or paperboad us,rg the prc:ess defned m this s:a.ac repulpable - le test matena! vruch ca udergo the operation of rev:mg ad fberzing fr subsequent st,eet foratior. uing _the process defned.in �i5 s,adac source·separati•on - the segrega�ior, a:C collection oi ind1viduai rec�c!able component at the point of .eneratior,., before te become mixed into the solid wat� ,�rea.. .. , . .. . . 1 . . . . . ,. ". treated corru.gated -· is the cotbined boad or boxes which-have bee� subjected to a specifc trea_tmentJor the :purose of improving the .perforace of corgatec rn the Pesence. of water _or water vapr The level (f treatment used tn the test must be.equal· · to or gre�ter than the level of treatment to be used in the feld. . . untreated corrugated - .is combined boad or boxes which have not ben .subjected to .y treatment fr any purose, including treatments fr improving the perforance of corgated in the presence of water or water vapor :.r . ,.. � ,' '. ,l '.: \ q.·. ' 4. Test Method 42 Preliminar Analysis: befre bcginnin� the test protocol. determine th� moisture Jnd "extract.blcs" content of the trelted corugated sJmple. P-RT 1: Rcpulplbili�· A I 00% charge of treated corgated 1s repulped in a Bnt1sh Dis1ntegrator in arifcially hardened water at a pH of 7 (±0.5 pH) that 1s maintained at l 35 ° F (: S:'} for 75.000 cycles. The pulped material 1s sepaated in a screen with O 010 inch slots io deterine fber recovery as a percenlge of the aount of fber chaged The aount of coating material deposited on a coupon tn the disintegrator 1s used to measure treatment deposition during repulping. Detailed procedues for repulpabilir are given in Appendix A. PART 2: Recydabilit Mix l 0% treated corgated ad 90% of the sae untreated corgated in a laborator-scale pulper at. pH 7 (±0.5 pH) ad l35°F (± 5 °) A chage of 100% Jntreated corgated is also pulped using identical conditions, a a contol. Each pulpd materal is pased though (in succession) a pressure scrcel equipped with a baket wth O 062 inch holes. the sae screen equipped wnh a baket with 0.0 IO inch slots ad a reverse centrfugal separator under conditions specifed in the procedure Hadsheets ae made from te fnal stage (cleaer) accepts with a recirculating white water system. discading the frst six hadshcets to afect te prop, build-up of materals in the white wate� For each batch tester. te hadsneets ae pressed ad dned 'NlL� neat ad tested for produc: prforace propries Proper1es include siide agle. tensi;e energy absortion (TEA). snor spa compress1v� strengt' STFi . bursting suengtr, ac wate� :�J: penetration. using the es:abi1shed T APPi of· . .1a, tes� me;nocs The prope;1es ac appea;ace of the handsheets fom the treatec ad untrea'7: co:Jpted tes:s will be c.:,mpaea De:ilec procedues fr rec:clabtlity are given m Appendix B. 5. Performance Levels ' .,-_ T;eated corgated satisfing all of-the·.requiremems of the volunta standard will be regarded as repulpable ad recyclable. There ae thee general perfnace requiiement; fber yield, operational impact ad product requirements. The material to be used a the contol must b untreated combined board with an "extractatles" contents 0.5%. Use the stadad "extraction" method approprate to the treatment being evaluated fr this deterination. I· , 'I ' . : '. \. \ I Fiber yield from the rcpulpability test must be at least 85%. based on the fiber charge to the pulper. 43 Opcr:tional impact is acceptable if I) the entire procedure can b completed w11hout clelning th< hadsheet screens or pressure screen baskets. and 2) thlre 1s no me:suratde depos1t1on of tre:tment on the coupon ad no , 1s1ble depos1t1on of treatment on .ir.� ;Ji.l!1 of the d1s1n1e;rator. Product requirements are satisfed 1i l. The appearance of the treated corgated handsheet shows no substantial difference fom hadsheets made fom the control. 2 The decreae in the mea slide agle of the saple hadsheets made using treated corgated ad the mea from the hadsheets made from the untreated corgated must be no greater tha l 0% 3. TEA. STFl. ad burs, stength, noralized to the sheet bais weight must show no signifcat decreae from the respective values fr te contol, at tte 95% statistical · .. · confdence levels fr tose meauement. 4. Te water drop penetation of hadsheets made fom teated corgated must not exceed the water drop penetration of the contol hadsheet by more than 200 seconds. 6. Cerifcatfon/Markog 6.1 Test fr Parts l ad 2 ac repeated tice. [f te treated corgated pases all test on bot tals. it satisfes te stdad If it pases all test on one tal. but fails some on the oter. it may be retested in a third tal. The treated corgated mut pas all test in the tird tal to satisf te stdad. 6.1 Maufa.ter oi teated corgated or corgated teatent ma: cerify teir ow product by umg ay capable laboratory , working m accordac� wnh te detiled protocoi provided 1n tis stadac Treated corgated m1s, be recemfed i: there is a:· signifcat chage tn teatent product. substate chemistr or ay increae m te .leye: o� t�eauent. Tne completed test repor fom Appendix C mut be submmec to AfP./FBA. R�pors wll b dcident1fed fr submission to a Stding Cornee for ue in penodic revie' of ths volut stdad by te Stading Comiree. 6�3 :'-1ar-kiog Te repulpablerecyclable cerification making (a show below) must clealy appea on the bx with the asigned AF PN"BA reference number Te bx maufcrurer's nae must appea on te box a well a the repulpablerecyclable cenifcation mak. . ;, l· ... ,, . '_-.,. ' ., '• r • ~ · ... , . . ' ...... ·, ' . . ,q. ,J .. • jr) I .... · \I. !· I APPENDIX A REPULPABILITY TEST PROCEDURE 44 I. Obtain a representative saple of the tre:ued corug:ned to be evaluated. Use fnished corgated containers. From this sample, select at least 80 g oi material fr test. Selecuon should be l representative l possibl of the mate�:JI JS J whole 1 Cut the select�j saple material into appro:1matel:, Ix I inc:. ;1eces Determine and record the moisture (TAPP! T 412] and "extractables" conten: 3. Firly fx a clea, c,rcula coupon of steel foil to the botom of the cylinder of a British O,sintegrator (T APPi T 205) The coupon should be approximately the sae diaeter as the dis1ntegrator impeller. rigid enough to withstad the ag1tat1on and of kow mass and aea. ·, 4. Place 24 g of saple material in the disintegrator ad add 2L of deionized water. · Raise "the wat�r hadness to 80-·100 ppm with calc1um 'chloride ad heat water to l 35 °F (± 5° ). Calculate the aout of fber in the chage, using the moisture ad "extractables" cont�nts_fo� Step 2. _ . , . . . . . , .. . . __ ., .· .,· 5. Adjust� if necessa, ad maintain the pH at 7 (: 0.5 pH wt dilute acid qr bae, ad repulp fr 15,000 revoluuons. maintaning l 35° F (= 5 °) by placing the disintegrator in a water bath or heating matle held at that temperature. 6 Chage the hot slu from te disintegrtor to a O O IO inch sloted opening laborator vibrating fat screen, preheated to l35 °F (= 5 °) Flush with: - 3 gpm oitap ·.,ateF, heated to I 3 5 �F ( � 5.0 )-fr 20 minutes. catc h1ng the accept which pas _though te scr�en. ip _a 200 mesh screen b) 7 Place te accept from te screen bx in a lage beaer or pa1.. diiute to a kow volume w1&. 'ater heated to l35 ° F (: 5 ° ; ad deterine the.ons1ste:c�JT.A.P'.:T.240J or (dJ�r the �ntire aout tough a Buc:er feL press.ad d' tr ::e over so as to accUately determine te mas of accepted solid materal. Air d ad de;efne te mo.is�e content [ .�Pl T 4 l 2] ac "ext:actble" content Deterine ;e aout of fber accepted Tn1s aou: divided b�· the aount o: fbc� chage: 'Step 6) lS the yield of �he sapl�. 8. Repea� Steps 4 tough 7 fr a second 24g sample of treated corgated. 9. Remove the coupon (Step 3) fom the disintegrator. gently wah wt deionized water, air dr and "e-gh. Deterine and repr the weight iain of the coupon. __ . . I 0. "oughout the procedure. look fr depsitions on the walls of te vessels ad on the screens. Note the presence or absence of deposits in the repor. . • ..•• - ,. ;.7 ... •. :._ · • t'- : ; • I . ; ,, . '-· ·�.-�. -· .. - :: -�J:.:. :. Dr, ,.\ r·· r, APPENDIX B RECYCLABILITY TEST PROCEDUR 45 Note: Pulp should ne�cr be allowed to exceed 140° F. I. Obtain a sample representative of the treated corrugated to be evaluated. Lise finished corrugated containers. From this sample. select IO lbs of m;itenal fortest Selection should be as ,epresentat1ve a:; possible of the material as a whole .Also obtain at least 90 lbs of Wltreated corrugated from the same base material as that which hasbeen treated. 1 Cut selected sample materialsinto approximately 7x 15 inch pieces with a suitable apparatus( i e. power band saw) Determinethe moisturecontent [T APPi T 412] and "extractable" content of thetreated and untreated samples • 3. Selection of the charge size will depend upon the capacity of thelaborato ry pulper to be used. Pulping is to be carried out at 3% consistency. Thechar ge will consist Of JO¾ (by .weight) of the treated corrugated to be tested and 90% of the untreated corrugated. Calculate the perc<:ntage of treatment material charged, based on oven dry fiber weight in the charge. Bring theequipment to I 35°F (±5�). Adjust thepH of the charge so that after pulping the pH will be qe ual to 7 (± 0.5 pH). Charge the pulper and raise the temperature to.\35°F (± 5 °). Pulp for 15 minutes while maintaining 135°F (± 5 °). 4. Repeat Step 3 until sufficient material has been obtained for the following steps. Maintainthe temperature of the pulp at l 35°F (± 5°) until it is used in Step 7 .. % 5. Combine thepulp from several batches. as necess. ary, and dilute to 1 consistency with water heated to 135 °F (: 5° ). AdJU.St the pH to 7 .(: 0.5 pH). Preheat a.scre�n W1th ° ° 0.0.625 inch holes to l35 F (::5 : and maintam the temper:m.ire throughout this screening step. Pass the pulp sample through thepreheated screer. at a volumetric reject rate of 10% of the feed rate. 6 Wi� the accepts from Step 5. repeat the procedure in Step 5 using a screen basket with 0.0 l C inch slots. ag.im maintairung the temperature, �onsistency and a I 0°/o reJect rate. 7. Pass the accepts from Step 6 through a reverse centrifugal-t'yl'C cleaner. maintaining Ll-ie :) 0 temperature at I 35 F (� ) and consistency. and the pressure differential specified for thecleaners being used Determine the volurnetncreject rate andreport. NOTE: -If the test must be halted to clean ANY apparatus in ANY aspect of this procedure, discontinue the procedure and report the test as a failure. . , . 1-11 , 11 ! .· \.)i . l) R . ..\I.,., 8. From the accepts from Step 7, form handshccts according to TAPP! T 205 with the following condiltons: 46 The slurry should be maintained at l 35°F (± 5°) and pH 7 (:tO S pH). Form anddiscard six standard ( 1 2 g) handsheets. using recirculated water. Accept the se,enth .inJ succeeding handsheets until the number required for the tests has been made Dry the sheets under restraint to 7% moisture content on a surface dryer maintained at 250 -275° F. Test the handsheets [TAP Pl T 220] for: Basis Weight. Caliper, Apparent Density Slide Angle [T APPI T 81 S] Tensile Energy Absorption. (TEA) [TAPPI T 494] Short Span Compression (STFl) [TAPP! T 826] Bursting Strength Water Drop Penetration (T APPI T 819) using theprocedures referenced in T APPI T 220 where not specifically designated above. 9. Calculate, on a sheet-by-sheet basis, the index of each of the strengthtests (Burst, etc.) i.e. test result . basis weight, and the meansof these indexed values for the sample set. Repon these results. the volumetric reject rate used in Step 7. any observations of deposition in anystage of theprocess, the appearance of the handsheets and any deviations from thJs procedure All tests must be performed on both the treated and untreated corrugated IO Repon the results using the form provided . . ...; 11 I I!' •·:. 47 Appendix III List of Samples Used forThesis Project Baseline Sample for Comparison Random sample of old newsprint Random sample of old corrugated containers Unknown 42# liner sample fromlocal supplier Molded Pulp Samples Laserj et toner innerpack Small bleached lightbulb trayP Medium bleached lightbulb tray P Medium kraftlightbulb tray P Large bleached lightbulb tray P Egg carton Pump top innerpack* Fast fooddrink tray Unwaxed pallet* Waxed pallet* Television innerpack Large steam cleaner innerpack* Small steam cleaner innerpack* Fruit tray Flower pot P Denotes those samples tested in conjunction with Plainwell Paper Co. * Denotes those samples tested in conjunction w/ Willamette Industries WCDL 48 Appendix IY Clark Classifier Fiber Classification Data Sample Initial Weight of Stock Total Percent of Weight of Filter Paper Sample Sample Filter Paper and Stock Weight 1-1 2.120 2.145 0.025 0.3 1-2 1.442 4.860 3.418 42.5 1-3 1.467 3.369 1.902 23.7 2-3 1.466 3.040 1.574 34.7 2-4 1.510 3.493 1.983 4.533 43.7 3-2 1.525 3.999 2.474 41.3 3-3 1.488 2.875 1.387 23.1 3-4 1.500 3.611 2.111 5.992 35.2 4-1 1.527 1.575 0.048 0.7 4-2 1.494 4.370 2.876 44.9 4-3 1.472 3.107 1.635 25.5 5-1 1.486 1.618 0.132 1.9 5-2 1.505 3.770 2.265 32.8 5-3 1.502 3.400 1.898 27.5 5-4 1.527 4.129 2.602 6.897 37.7 6-1 0.000 6-3 0.000 6-4 0.000 0 7-1 1.500 1.520 0.020 0.3 7-2 1.534 3.930 2.396 36.4 7-3 1.495 3.380 1.885 28.7 7-4 1.500 3.774 2.274 6.575 34.6 8-1 1.488 1.515 0.027 0.4 8-2 1.497 3.950 2.453 39.8 8-3 1.525 3.100 1.575 25.5 8-4 1.466 3.580 2.114 6.169 34.3 9-1 1.469 1.563 0.094 1.4 9-2 1.480 3.897 2.417 36.1 9-3 1.490 3.319 1.829 27.3 9-4 1.520 3.881 2.361 6.701 35.2 10-1 1.483 1.490 0.007 0.1 10-2 1.521 3.800 2.279 34.9 10-3 1.491 3.455 1.964 30.1 10-4 1.468 3.750 2.282 6.532 34.9 11-1 1.455 1.842 0.387 4.7 11-2 1.494 4.491 2.997 36.3 11-3 1.417 3.272 1.855 22.4 11-4 1.453 4.477 3.024 8.263 36.6 12-1 1.466 2.122 0.656 7.7 12-2 1.494 5.020 3.526 41.6 12-3 1.465 3.577 2.112 24.9 12-4 1.453 3.630 2.177 8.471 25.7 13-1 0.000 13-2 0.000 13-3 0.000 13-4 0.000 0 14-1 1.500 1.640 0.140 1.7 14-2 1.520 4.660 3.140 38.1 14-3 1.480 4.870 3.390 41.1 14-4 1.510 3.090 1.580 8.25 19.2 15-1 1.480 1.499 0.019 0.3 15-2 1.462 3.990 2.528 39.2 15-3 1.481 3.171 1.690 26.2 15-4 1.432 3.650 2.218 6.455 34.4 16-1 1.467 1.820 0.353 5.2 16-2 1.469 4.075 2.606 38.2 16-3 1.481 3.250 1.769 25.9 16-4 1.519 3.611 2.092 6.82 30.7 17-1 1.505 2.030 0.525 7.0 17-2 1.455 4.396 2.941 39.1 17-3 1.430 3.420 1.990 26.5 17-4 1.469 3.535 2.066 7.522 27.5 18-1 1.490 1.760 0.270 3.9 18-2 1.450 4.130 2.680 38.4 18-3 1.492 3.471 1.979 28.3 18-4 1.498 3.552 2.054 6.983 29.4 19-1 1.481 4.224 2.743 29.2 19-2 1.453 4.930 3.477 37.0 19-3 1.504 3.135 1.631 17.3 19-4 1.466 3.017 1.551 9.402 16.5 20-1 1.442 2.518 1.076 13.5 20-2 1.465 4.641 3.176 39.8 20-3 1.506 3.391 1.885 23.6 20-4 1.496 3.336 1.840 7.977 23.1 21-1 1.439 1.785 0.346 4.4 21-2 1.468 3.843 2.375 30.1 21-3 1.500 3.640 2.140 27.1 21-4 1.470 4.510 3.040 7.901 38.5 51 Appendix Y Raw Data from RecyclabilitySection Bleached Sample# Weight Basis Weight Caliper Density Opacity Smoothness Tensile Mullen Scott Bond (grams) (lb/1000ft2) (mils) (lb/ft3) (%) (microns) (lb/in) (lb/in2) (ft*lb)*10-3 1 8.8 43.6 19.91 26.3 43.9 9.55 37.3 45.5 80 72 80 2 8.8 43.6 21.1 24.8 44.7 9.69 32.6 39 46 62 46 3 8.8 43.6 21.49 24.4 44.6 9.84 28.4 38.5 69 90 85 4 8.5 42.1 19.78 25.6 45.4 10.03 39.6 43 46 76 78 5 8.6 42.6 21.1 24.2 43.7 9.91 36.3 44.5 67 92 72 6 9 44.6 19.08 28.1 44.7 9.93 32.7 35.5 57 71 7 8.4 41.6 20.47 24.4 45 9.98 41.3 40.5 74 76 8 9 44.6 20.67 25.9 44.1 9.78 32.3 39 48 72 9 8.8 43.6 20.32 25.8 44.4 9.89 43.3 41.5 69 80 10 8.6 42.6 22.7 22.5 44.4 9.77 38.7 41 62 67 AVG 8.7 43.3 20.7 25.2 44.5 9.8 36.3 40.8 69.5 ·------·· ·-· -- STD 0.2 1.0 1.0 1.5 0.5 0.1 4.7 3.0 13.1 ------· ----· ------·- HIGH 9.0 44.6 22.7 28.1 45.4 10.0 43.3 45.5 92.0 ------·- LOW 8.4 41.6 19.1 22.5 43.7 9.6 28.4 35.5 46.0 ------COUNT 10 10 10 10 10 10 10 10 25 Groundwood Sample# Weight Basis Weight Caliper Density Opacity Smoothness Tensile Mullen Scott Bond (grams) (lb/1000ft2) (mils) (lb/ft3) (%) (microns) (lb/in) (lb/in2) (ft*lb)*10-3 I 1 9.3 46.1 21.93 25.2 36.2 9.54 51.7 52.5 92 87 I 88 2 9.4 46.6 23.06 24.2 45.1 9.18 56.1 54.5 88 90 I 80 3 9.6 47.6 23.85 23.9 44.7 9.07 58.3 56.5 85 98 72 4 9.7 48.1 22.83 25.3 38.5 9.29 48.8 50 94 67 62 5 9.8 48.6 23.08 25.3 43.8 8.91 50.7 63 94 68 93 21.38 24.5 6 8.8 43.6 -- 41.2 9.67 51.2 58.5 85 74 7 8.7 43.1 20.74 24.9 37.2 9.88 53.4 51.5 86 109 8 8.7 43.1 22.06 23.5 37.3 9.23 59.6 51 76 96 9 8.1 40.1 19.71 24.4 38.2 9.35 54.2 54 106 85 19.81 I 10 8.3 41.1 24.9 36.8 10.08 49.4 63.5 92 88 I AVG 9.0 44.8 21.8 24.6 39.9 9.4 53.3 55.5 86.2 ------·- . - - - -· ------·--· - - ---��-- - -- STD 0.6 3.0 1.4 0.6 3.5 0.4 3.7 4.8 11.5 I ------� ------HIGH 9.8 48.6 23.9 25.3 45.1 10.1 59.6 63.5 109.b ------LOW 8.1 40.1 19.7 23.5 36.2 8.9 48.8 50.0 62.0 ------. ---·------• ------COUNT 10 10 10 10 10 10 10 10 25 I Group #17 Sample# Weight Basis Weight Caliper Density Opacity Smoothness Tensile Mullen Scott Bond 3 (grams) (lb/1000ft2) (mils) (lb/ft ) (%) (microns) (lb/in) (lb/in2) (ft*lb)*10-3 I 1 9 44.6 19.8 27.0 45.2 10.45 34.3 38 70 71 iI 70 2 8.8 43.6 18.7 28.0 43.4 10.6 30.8 35 98 60 52 3 8.5 42.1 16.61 30.4 45.4 10.37 34 36 60 55 55 4 9.1 45.1 17.89 30.3 45 11.2 27.6 30 63 54 51 5 8.9 44.1 17.76 29.8 44.9 10.34 33.2 42 55 69 60 6 8.6 42.6 16.6 30.8 45.1 10.6 30.8 36 70 72 7 8.7 43.1 18.56 27.9 45.3 10.3 32.3 30 65 67 8 8.8 43.6 17.63 29.7 45 9.99 29.3 33 65 60 9 8.8 43.6 17.34 30.2 43.9 10.46 25.7 42 67 60 10 9.3 46.1 18.17 30.4 43.5 10.2 29 32 67 61 l AVG 8.9 43.9 17.9 29.5 44.7 10.5 30.7 35.4 63.9 ---- � ------·-·------· . - - . - ---· - STD 0.2 1.2 1.0 1.3 0.8 0.3 2.8 4.4 9.5 ------HIGH 9.3 46.1 19.8 30.8 45.4 11.2 34.3 42.0 98.0 ------LOW -8.5 42.1 16.6 27.0 43.4 10.0 25.7 30.0 51.0 - --I - --,___. -·------COUNT 10 10 I 10 I 10 I 10 10 10 10 25 Kraft Sample# Weight Basis Weight Caliper Density Opacity Smoothness Tensile Mullen Scott Bond 3 (grams) (lb/1000ft2) (mils) (lb/ft ) (%) (microns) (lb/in) (lb/in2) (ft*lb)*10-3 1 9.2 45.6 20.7 26.4 28.1 11.06 29.8 32 32 33 32 2 9.2 45.6 21.8 25.1 28.1 10.67 33.7 28 28 30 36 3 8.9 44.1 21 25.2 28.4 10.77 32.5 42 34 30 30 4 9.2 45.6 21.1 25.9 28.8 10.7 30.6 50 36 27 36 5 8.9 44.1 21.08 25.1 28.5 10.78 33.8 35 40 29 32 6 8.9 44.1 19.68 26.9 29.6 10.97 30.5 35 40 28 I 7 8.6 42.6 19.46 26.3 28.7 10.75 33.2 31 44 34 8 9.2 45.6 20.13 27.2 29.3 10.98 38.2 28 38 30 -·�- -- -- 9 9.3 46.1 20.2 27.4 29.3 10.84 34.5 33 39 32 10 9.2 45.6 20.01 27.3 29.5 11.07 33.3 41 46 32! AVG 9.1 20.5 26.3 28.8 10.9 33.0 35.5 33.9; -- .. 44.9 - --. -�------· . - - STD 0.2 1.1 0.7 0.9 0.6 0.1 6.9 5.0 ... •·------·- -·-2.4- . -----·- - --- ! --- HIGH 9.3 46.1 21.8 27.4 29.6 11.1 38.2 50.0 46.0 ------· ------· -- - ·------1 - LOW 8.6 42.6 19.5 25.1 28.1 10.7 29.8 28.0 - -- 27_:0 . ---I ------1 COUNT I 10 10 10 10 10 10 10 10 25t Machine Made 42# Liner Sample Sample # Weight Basis Weight Caliper Density Opacity Smoothness Tensile Mullen Scott Bond 3 (grams) (lb/1000ft2) (mils) (lb/ft ) (%) (microns) (lb/in) (lb/in2) (ft*lb)* 10-3 1 8.4 41.6 10.34 48.3 27.1 8.59 93.5 120 112 101 109 2 8.5 42.1 10.56 47.9 27.3 8.71 94.2 104 118 117 131 3 8.5 42.1 10.6 47.7 27.9 8.62 93.4 116 127 96 114 4 8.4 41.6 10.39 48.1 26.4 9.28 93.5 103 135 116 99 5 8.5 42.1 10.33 48.9 28.2 8.8 93.8 108 114 106 92 6 8.5 42.1 10.29 49.1 28 8.41 92.7 117 122 103 7 8.6 42.6 10.39 49.2 27.6 8.88 91.7 113 103 112 8 8.6 42.6 10.45 48.9 27.4 8.88 92.5 120 108 95 9 8.5 42.1 10.26 49.3 28.4 8.69 93 115 101 99 10 8.4 41.6 10.46 47.8 28.3 8.52 93.2 77 94 92 AVG 8.5 42.1 10.4 48.5 27.7 8.7 93.2 109.3 108.6 ------STD 0.1 0.4 0.1 0.6 0.6 0.2 0.7 12.9 12.1 - -- - HIGH 8.6 42.6 10.6 49.3 28.4 9.3 94.2 120.0 135.0 - · ·------·------LOW 8.4 41.6 10.3 47.7 26.4 8.4 91.7 77.0 92.0 ------·------�---- - COUNT 10 10 10 I10 10 10 10 10 l 25 MMCD Sample# Weight Basis Weight Caliper Density Opacity Smoothness Tensile Mullen Scott Bond 3 (grams) (lb/1000ft2) (mils) (lb/ft ) (%) (microns) (lb/in) (lb/in2) (ft*lb)*10-3 53.2 123 101 116 47.2 113 103 116 50.4 108 108 114 50.9 116 125 112 51.5 112 99 130 51.9 105 98 50.7 105 92 49.4 116 114 1 48.1 112 97 I 48.9 117 97 AVG 50.2 110.0 I -- -- -· ------I STD 1.8 9.5 - --- ·- -· �- - --�--- - I- - -- ·-- - - HIGH 53.2 130.0 ------•· -- - LOW 47.2 92.0 -· j - -· -·------COUNT I 10 251 Pallet Sample# Weight Basis Weight Caliper Density Opacity Smoothness Tensile Mullen Scott Bond 3 (grams) (lb/1000ft2) (mils) (lb/ft ) (%) (microns) (lb/in) (lb/in2) (ft*lb)* 1 0-3 1 8.2 40.6 16.18 30.1 46 10.33 32.3 31 72 60 62 2 8.2 40.6 15.83 30.8 44 10.11 29.1 36 80 63 65 3 9.4 46.6 19.19 29.1 45.6 10.43 40.9 32 76 53 I 63 4 8.6 42.6 16.94 30.2 10.3 38.7 32 73 55 I 63 46 I 5 8.6 42.6 17.11 29.9 45.2 10.65 33.2 28.5 63 62 60 6 8.1 40.1 16.1 29.9 44.1 10.17 35.4 40.5 53 55 7 9.6 47.6 17.5 32.6 43.8 10.27 34.7 33 55 67 8 9.7 48.1 16.32 35.3 46.1 10.36 26.7 38 54 55 9 8.8 43.6 17.58 29.8 46.1 10.18 33.8 29.5 60 67 10 9 44.6 17.79 30.1 45.8 10.6 33.2 30.5 63 58 AVG 8.8 43.7 17.1 30.8 45.3 10.3 33.8 33.1 62.3 ·-----· -· - - -- ·------STD 0.6 2.9 1.0 1.8 0.9 0.2 4.1 3.9 7.2 - -- _,___ --- >---·- ·-- .. -- - - HIGH - 9.7 48.1 19.2 35.3 46.1 10.7 40.9 40.5 80.0 ------� - ,_ -- --�- LOW 8.1 40.1 15.8 29.1 43.8 10.1 26.7 28.5 53.0 - - COUNT 10 10 10 10 10+ 10 10 10 25 I Sample 1.0. Ub.l1QQQ1l Basis Weight Calipr zl � Mall Min � � Mall Min Control • Gray 44.8 3 48.6 40.1 21.8 1.4 23.9 19.7, 43.3 1 44.6 41.6 20.7 1 22.71 19.1, W� __j ___ ------Light Brown 43.9 1.2 46.1 42.1 17.9 1 19.8 16.6 1 Pa1Iet" - l� 43.7 --- 2.9 ---48.1 10.4 17.1 1 19.2 15.8 - L -f----- Control•--- • Brown------I 44.9 --1.1- 46.1 42.6 20.5 0.7 21.8 19.5 42# Liner 42.1 0.4 42.6 41.6 10.4 0.1 10.6 10.3 I Smothness Tensile � � I Mall Min !!.bLinl � Mall Min Control • Gray 9.4 0.4 10.1 8.9 53.3 3.7 59.6 48.8 Wite 9.8 0.1 10 9.6 36.3 4.7 43.3 28.4 Light Brown 10.5 0.3 11.2 10 30.7 2.8 34.3 25.71 Pallet 10.3 0.2 10.7 10.1 33.8 4.1 40.9 26.7 Control - Brown 10.9 0.1 11.1 10.7 33 2.4 38.2 29.8 42# Liner 8.7 0.2 9.3 8.4 93.2 0.7 94.2 91.7 Density Opacity ilblfl�l � Mall Min 00 � Mall Min Control • Gray 24.6 061 25.3 23.5 39.9 3.5 45.1 36.2 Wite 25.2 1.5 28.1 22.5 44.5 0.5 45.4 43.7 Light Brown 29.5 1.3 30.8 27 44.7 0.8 45.4 43.4 Pallet 30.8 1.8 35.3 29.1 45.3 0.9 46.1 43.8 Control • Brown 26.3 0.9 27.4 25.1 28.8 0.6 29.6 28.1 42# Liner 48.5 0.6 49.3 47.7 27.7 0.6 28.41 26.4 I I I I I I Mullen Sctt Bond ill2linzl I � MIDS Min � � MIDS I Min I I Control • Gray 55.5 4.8 63.5 50 86.2 11.51 109 62, Wite I 40.8' 3, 45.5 35.5 69.5 13.1 I 92 461 Light Brown 35.4; 4.4 42 30 63.9 9.5 98' 51 Pallet ' 33.1 3.9 40.5' 28.51 62.3 7.2 80 53 Control • Brown I 35.5 6.9 50 28 33.9 5 46 27 1 ' 42# Liner I 109.31 12.9 120, 77 108.6 12.1 135 92