Paper and Board Manufacture and Properties Workshop

PaperPaper andand BoardBoard ManufactureManufacture andand PropertiesProperties WorkshopWorkshop CharlesCharles P.P. KlassKlass KlassKlass AssociatesAssociates Inc.Inc. RedingtonRedington Beach,Beach, FLFL SummarySummary ofof WorkshopWorkshop z OverviewOverview andand terminologyterminology ofof paperpaper andand boardboard gradesgrades thatthat areare extrusionextrusion coatedcoated z PropertiesProperties ofof paperpaper andand boardboard usedused forfor extrusionextrusion coatingcoating z PaperPaper andand boardboard manufacturingmanufacturing variablesvariables thatthat impactimpact extrusionextrusion coatingcoating z TrendsTrends andand developmentsdevelopments z GeneralGeneral groupgroup discussiondiscussion ExtrusionExtrusion CoatedCoated GradesGrades z ExtrusionExtrusion coatingcoating isis appliedapplied toto aa widewide varietyvariety ofof paperpaper andand boardboard gradesgrades dependingdepending onon thethe propertiesproperties soughtsought z ExtrusionExtrusion coating/laminationcoating/lamination cancan bebe usedused toto bondbond foilfoil toto paperpaper oror paperboardpaperboard forfor enhancedenhanced barrierbarrier propertiesproperties ExtrusionExtrusion CoatedCoated GradesGrades

Substrate Property Sought End Uses

Bag and wrapping MVTR, OGR, QSR, bakery, paper liquid resistance carry-out, multiwall sacks Bleached board Liquid resistance Cups, milk cartons

Linerboard MVTR, OGR, Frozen food & liquid resistance, other packaging release VariabilityVariability ofof PaperPaper z PaperPaper isis notnot aa homogeneoushomogeneous material.material. z VariesVaries inin thethe machinemachine directiondirection (MD),(MD), crosscross-- directiondirection (CD),(CD), ZZ--direction,direction, andand overover time.time. z ItIt isis alsoalso reactivereactive toto changeschanges inin itsits environment.environment. ShrinksShrinks andand expandsexpands andand usuallyusually notnot uniformly.uniformly. z ItsIts structurestructure dependsdepends onon thethe processprocess thatthat producedproduced itit andand eveneven thethe locationlocation acrossacross thethe widthwidth ofof thethe paperpaper machine.machine. VariabilityVariability ofof PaperPaper ComponentsComponents ofof WoodWood

z CelluloseCellulose –– 45%45% Wood Tissue z LigninLignin –– 25%25% z HemicellulosesHemicelluloses –– 25%25% z ExtractivesExtractives –– 5%5% Cambium

Inner Bark CelluloseCellulose (C(C66HH1010OO55))nn FiberFiber StructureStructure

PAPRICAN FiberFiber StructureStructure

Lumen S3 Layer

Lignin Lignin S2 Layer

Primary wall S1 Layer

Middle lamella FiberFiber StructureStructure

z LikeLike aa drinkingdrinking strawstraw z 1/321/32”” (0.75mm)(0.75mm) toto 1/41/4”” (6mm)(6mm) longlong z LengthLength toto widthwidth ratioratio ofof 5050 toto 140140 FiberFiber StructureStructure FiberFiber StructureStructure

Pine sheet Eucalyptus sheet FiberFiber StructureStructure z SoftwoodsSoftwoods forfor strengthstrength andand runnabilityrunnability z HardwoodsHardwoods forfor uniformity,uniformity, smoothness,smoothness, formation,formation, andand printabilityprintability z InherentInherent strengthstrength requirementrequirement ofof thethe convertingconverting processprocess dictatesdictates thethe amountamount ofof softwoodsoftwood thatthat isis includedincluded inin thethe furnishfurnish PulpingPulping andand BleachingBleaching z 65%65% ofof thethe pulppulp producedproduced inin thethe worldworld isis mademade byby thethe kraftkraft process.process. z ChemicalChemical pulpingpulping removesremoves mostmost ofof thethe ligninlignin andand hemicelluloseshemicelluloses andand allall ofof thethe extractives.extractives. z However,However, chemicalchemical pulpingpulping resultsresults inin darkdark brownbrown pulppulp thatthat mustmust bebe bleached.bleached. z NearlyNearly allall extrusionextrusion coatedcoated paperpaper andand boardboard isis mademade fromfrom kraftkraft pulp.pulp. PaperPaper StructureStructure z CelluloseCellulose moleculemolecule isis alignedaligned moremore oror lessless parallelparallel toto thethe longlong axisaxis ofof thethe fiber.fiber. z FibersFibers areare hydrophilic.hydrophilic. z FibersFibers expandexpand andand shrinkshrink basedbased onon thethe waterwater contentcontent inin thethe fiberfiber walls.walls. z FibersFibers cancan swellswell upup toto 25%25% inin widthwidth butbut onlyonly slightlyslightly inin length.length. z HydrolysisHydrolysis resultsresults inin fiberfiber swelling,swelling, greatergreater fiberfiber flexibility,flexibility, andand fiberfiber collapse.collapse. PaperPaper StructureStructure

Page PaperPaper StructureStructure

Side view

Top view

More fiber collapse Less fiber collapse PaperPaper StructureStructure

FiberFiber collapsecollapse dependsdepends on:on: z ThicknessThickness ofof thethe cellcell wallswalls z RatioRatio betweenbetween fiberfiber wallwall thicknessthickness andand fiberfiber widthwidth z AmountAmount ofof ligninlignin leftleft inin thethe fiberfiber wallwall z AmountAmount ofof mechanicalmechanical actionaction z PressurePressure onon thethe paperpaper machinemachine PaperPaper StructureStructure PaperPaper StructureStructure PaperPaper StructureStructure

Fiber orientation means that paper is stronger in the machine direction than in the cross machine direction. PaperPaper StructureStructure PaperPaper StructureStructure

z MoreMore fiberfiber alignmentalignment inin thethe MDMD isis calledcalled anisotropy.anisotropy. z SonicSonic modulusmodulus relatesrelates toto tensiletensile stiffnessstiffness indexindex (TSI).(TSI). z TSITSI relatesrelates toto fiberfiber orientation.orientation. PaperPaper StructureStructure

z TSOTSO isis thethe angleangle ofof maxmax TSO TSI.TSI. z MightMight notnot bebe inin thethe exactexact MD.MD. z VariesVaries acrossacross thethe sheet.sheet. z CalledCalled asymmetricalasymmetrical anisotropy.anisotropy. PaperPaper StructureStructure z FibersFibers swellswell inin width,width, butbut notnot inin length.length. z HumidityHumidity changeschanges affectaffect thethe CDCD moremore thanthan thethe MD.MD. z SameSame problemproblem ifif toptop andand bottombottom ofof thethe sheetsheet isis different.different. z PaperPaper curls.curls. SummarySummary ofof PapermakingPapermaking z PaperPaper isis aa recordrecord ofof allall thethe processesprocesses thatthat havehave occurredoccurred inin itsits production,production, andand thosethose processesprocesses areare inherentlyinherently unstable.unstable. z TheThe physicalphysical propertiesproperties ofof paperpaper areare basedbased onon thethe structurestructure ofof thethe cellulosecellulose molecule,molecule, thethe typetype ofof fiber,fiber, andand howhow thatthat fiberfiber waswas separatedseparated fromfrom thethe otherother componentscomponents ofof thethe wood.wood. z TheThe wayway thethe fibersfibers areare reassembledreassembled stronglystrongly affectsaffects howhow thethe paperpaper reactsreacts toto furtherfurther convertingconverting operationsoperations andand otherother changeschanges inin itsits environment.environment. BaseBase StockStock QuestionsQuestions zzEndEnd useuse requirements?requirements? zzIsIs thethe basebase stockstock mademade toto bebe coated?coated? zzAreAre youyou makingmaking oror buying?buying? zzCanCan youyou specifyspecify oror mustmust youyou adapt?adapt? RollRoll QualityQuality forfor OffOff--MachineMachine CoatingCoating zz CleanClean slitslit edgesedges zz NoNo edgeedge crackscracks zz UniformUniform tensiontension -- nono wrinkleswrinkles zz NoNo holesholes zz SplicesSplices zzMinimalMinimal numbernumber zzProperlyProperly mademade andand markedmarked SpecifyingSpecifying BaseBase StockStock PhysicalPhysical PropertiesProperties z Basis weight z Moisture z Caliper z Strength z Tensile z Tear z Internal bond z Folding endurance z Porosity z Smoothness/roughness z Coefficient of Friction (COF) z Scoring and bending properties SpecifyingSpecifying BaseBase StockStock OpticalOptical PropertiesProperties

z BrightnessBrightness z ShadeShade z GlossGloss PaperPaper andand BoardBoard TestingTesting StrengthStrength PropertiesProperties z FoldingFolding EnduranceEndurance z ScottScott BondBond (Internal(Internal Bond)Bond) z StiffnessStiffness z BendingBending ResistanceResistance ofof PaperPaper –– GurleyGurley MethodMethod z StiffnessStiffness ofof PaperboardPaperboard –– TaberTaber MethodMethod z TearingTearing ResistanceResistance z TensileTensile StrengthStrength FoldingFolding EnduranceEndurance

z Folding endurance is tested using the MIT tester z A strip of paper is mounted under tension in the tester z The tester rotates back and forth through 270° z The number of double folds is reported – either as

raw data or log10 z ISO 5626 and TAPPI T 511 are the folding endurance test methods ScottScott InternalInternal BondBond z MeasuresMeasures thethe internalinternal bondbond strengthstrength z VeryVery criticalcritical forfor offsetoffset printingprinting –– especiallyespecially sheetsheet fedfed offsetoffset withwith highhigh tacktack inksinks z ResistanceResistance toto fiberfiber pickingpicking z TAPPITAPPI TT 569569 GurleyGurley StiffnessStiffness forfor PaperPaper z BendingBending resistanceresistance isis importantimportant forfor sheetsheet fedfed offsetoffset z SampleSample isis clampedclamped andand usedused toto deflectdeflect aa pendulumpendulum withwith weightweight z DataData isis reportedreported inin GurleyGurley stiffnessstiffness unitunit z TAPPITAPPI TT 543543 TaberTaber StiffnessStiffness forfor PaperboardPaperboard z DeterminesDetermines thethe bendingbending momentmoment inin gramgram centimeterscentimeters requiredrequired toto deflectdeflect thethe freefree endend ofof aa 3838--mmmm widewide samplesample 1515°° fromfrom itsits centerlinecenterline withwith aa loadload appliedapplied 5050 mmmm awayaway fromfrom thethe clampclamp z TAPPITAPPI TT 489489 ElmendorfElmendorf TearTear TesterTester z PaperPaper samplesample isis torntorn throughthrough aa fixedfixed distancedistance byby meansmeans ofof aa pendulumpendulum z TheThe workwork donedone inin tearingtearing isis thethe lossloss inin potentialpotential energyenergy ofof thethe pendulumpendulum z DataData reportedreported inin gramsgrams forceforce z TAPPITAPPI TT 414414 TensileTensile StrengthStrength

z Tensile strength is the maximum stress developed in a sample before rupture z Sample is clamped in a tensile tester and force applied to separate the jaws z Tensile strength is reported in Kn/m z Breaking length is the calculated limiting length of a hanging strip of paper that would break it z Tensile Index is tensile strength in N/m divided by grammage z ISO TC6 and TAPPI T 494 PaperPaper SurfaceSurface PropertyProperty TestingTesting z CoefficientCoefficient ofof FrictionFriction z PorosityPorosity z Air Resistance – Gurley Method z RoughnessRoughness z Sheffield Method z Parker Print Surf Method z WaxWax PickPick z WetWet RubRub CoefficientCoefficient ofof FrictionFriction z Static Coefficient of Friction by slide angle z Slide angle correlates to COF z TAPPI T 548 z Static and Kinetic COF by horizontal plane z Calculate COF by forces required to move z TAPPI T 549 AirAir PermeabilityPermeability –– GurleyGurley TestTest z Gurley tester consists of an outer cylinder partially filled with liquid and an inner cylinder with a 6.4 cm2 orifice and clamp z Paper sample is mounted in the clamp and the inner cylinder released to force air through the sheet z Time required for 100 ml of air to pass through the paper is recorded as Gurley seconds density z TAPPI T 460 SheffieldSheffield Smoothness/RoughnessSmoothness/Roughness z MeasuresMeasures airair flowflow betweenbetween thethe samplesample –– backedbacked byby aa smoothsmooth glassglass –– andand twotwo pressurized,pressurized, concentricconcentric annularannular ringsrings impressedimpressed intointo thethe samplesample fromfrom thethe toptop sideside z LowerLower numbernumber meansmeans smoothersmoother paperpaper z ReportedReported inin SheffieldSheffield unitsunits z TAPPITAPPI TT 538538 ParkerParker PrintPrint SurfSurf RoughnessRoughness z MoreMore preciseprecise airair leakleak measurementmeasurement z ClampingClamping pressurepressure cancan bebe variedvaried z 10 Kg is standard z AnnulusAnnulus isis 0.0510.051 mmmm z AirAir flowflow givesgives anan indicationindication ofof surfacesurface roughnessroughness

isis reportedreported asas µµmm withwith pressure,pressure, e.g.e.g. PPSPPS10 == 1.21.2 µµmm z DevelopedDeveloped forfor gravuregravure butbut widelywidely usedused forfor manymany typestypes ofof paperpaper andand paperboardpaperboard WaxWax PickPick TestTest z MeasuresMeasures surfacesurface strengthstrength z CalibratedCalibrated sealingsealing waxeswaxes withwith increasingincreasing adhesiveadhesive powerpower areare pulledpulled fromfrom thethe paperpaper surfacesurface z HighestHighest numbernumber thatthat doesdoes notnot teartear fibersfibers fromfrom thethe surfacesurface isis recordedrecorded z TAPPITAPPI TT 459459 WetWet RubRub TestTest –– AdamsAdams WetWet RubRub z MeasuresMeasures thethe resistanceresistance ofof thethe paperpaper surfacesurface toto wetwet abrasiveabrasive actionaction z KeyKey testtest forfor offsetoffset paperspapers z SampleSample isis mountedmounted onon wheelwheel andand rubbedrubbed withwith wetwet rollroll z MaterialMaterial abradedabraded formform surfacesurface isis washedwashed intointo bottlebottle withwith waterwater z TurbidityTurbidity ofof waterwater correlatescorrelates toto materialmaterial rubbedrubbed offoff andand isis reportedreported asas wetwet rubrub valuevalue PaperPaper TestingTesting OpticalOptical PropertiesProperties

z BrightnessBrightness z WhitenessWhiteness z ColorColor z DirtDirt CountCount z FadingFading z FluorescenceFluorescence z GlossGloss z OpacityOpacity

BrightnessBrightness z BrightnessBrightness isis percentagepercentage reflectancereflectance ofof lightlight atat wavelengthwavelength 457457 nmnm z ISOISO andand TAPPITAPPI (GE(GE Brightness)Brightness) methodsmethods differdiffer z TAPPITAPPI TT 452452 measuresmeasures throughthrough aa 457457--nmnm filterfilter andand isis basedbased onon magnesiummagnesium oxideoxide beingbeing 100%100% z ISO2469/2470ISO2469/2470 measuresmeasures overover aa rangerange ofof wavelengthswavelengths z TAPPITAPPI (GE)(GE) brightnessbrightness valuesvalues areare usuallyusually aa pointpoint oror twotwo lowerlower thanthan ISOISO brightnessbrightness valuesvalues BrightnessBrightness WithWith andand WithoutWithout UVUV FluorescenceFluorescence z BrightnessBrightness isis measuredmeasured withwith andand withoutwithout aa UVUV filterfilter toto determinedetermine fluorescencefluorescence andand thethe effecteffect ofof opticaloptical brightenersbrighteners z ModernModern brightnessbrightness testerstesters areare allall equippedequipped withwith UVUV filtersfilters andand alsoalso measuremeasure colorcolor inin termsterms ofof L,a,bL,a,b valuesvalues andand alsoalso measuremeasure whitenesswhiteness ColorColor

TAPPI Test Methods for color are T 442, T 524 and T 527 WhitenessWhiteness z WhitenessWhiteness isis measuremeasure ofof reflectancereflectance atat allall visiblevisible wavelengthswavelengths ofof lightlight z MeasurementsMeasurements areare mademade usingusing aa standardstandard D65D65 lightlight sourcesource toto getget colorcolor coordinatescoordinates z UV component of the D65 source is controlled to adjust for effect of fluorescent dyes z CalculationCalculation ofof whitenesswhiteness isis basedbased onon thesethese measurementsmeasurements z ISOISO 11475:200411475:2004 isis usedused forfor paperspapers withoutwithout OBAOBA z ISOISO 24692469 isis usedused forfor paperspapers mademade withwith OBAOBA GlossGloss z Gloss describes the mirror-like property of coated paper z Gloss is defined as the percentage reflectance at an angle equal to the angle of incidence compared with a standard surface z TAPPI T 480 measures at 75° and is the standard test z TAPPI T 653 measures at 20° and is commonly referred to as “Low Angle Gloss” OpacityOpacity

z OpacityOpacity isis aa measuremeasure ofof thethe amountamount ofof lightlight transmittedtransmitted throughthrough paperpaper z 100%100% opacityopacity meansmeans nono transmittedtransmitted lightlight z MeasurementMeasurement isis mademade byby comparingcomparing thethe reflectancereflectance ofof aa singlesingle sheetsheet overover aa blackblack backgroundbackground toto anan opaqueopaque stackstack ofof sheetssheets z OpacityOpacity testtest methodsmethods areare ISOISO 24712471 andand TAPPITAPPI TT 425425 WhereWhere GradesGrades AreAre ProducedProduced

Regional % of U. S. Production Grade South NE/NC West Uncoated Free 65 26 9 Coated Paper 23 73 4 Coated SBS 95 0 5 Coated SUS 100 0 0 Kraft Linerboard 83 0 17 U.U. S.S. PulpwoodPulpwood FiberFiber CharacteristicsCharacteristics Fiber Dimensions Wall Specific Length Diameter Thickness Species Gravity mm µm µm Loblolly P. 0.47 3.5-4.5 35-45 4-11 Doug. Fir 0.43 3.5-4.5 35-45 3-8 W. Hemlock 0.38 2.5-4.2 30-40 2-5 Spruce 0.37 2.5-4.2 25.-35 2-3 White Oak 0.59 1.4 14-22 5 Sweet Gum 0.44 1.7 20-40 8 Birch 0.48 08.-2.7 20-36 2-3 Aspen 0.35 0.4-1.9 10-27 2-3 PropertiesProperties ofof KraftKraft PulpsPulps byby SpeciesSpecies Tensile Maximum Coarseness Index Tear Index Species µg/m N·m/g mN·m²/g Spruce 140 135 20 W. Hemlock 190 120 18 Doug. Fir 264 90 30 Southern Pine 280 85 28 Oak 143 67 11 Gum 266 96 13 Birch 116 101 10 Aspen 129 103 8 StructuralStructural PropertiesProperties byby SpeciesSpecies Maximum Elastic Edgewise Bulk Modulus Compr. Index Species cm³/g kN·m/g N·m/g Spruce 1.7 8.1-9.0 40-43 W. Hemlock 2.0 8.2 37-41 Doug. Fir 2.1 6.5-8.5 31-33 Southern Pine 2.1 8.7 36 Oak 2.4 6.4 28 Gum 1.8 8.6 30-40 Birch 1.5 6.1 36.5 Aspen 1.5 43 BendingBending StiffnessStiffness S = kEc³ Where:Where: SS == StiffnessStiffness EE == YoungYoung’’ss modulusmodulus ofof elasticityelasticity cc == CaliperCaliper PaperPaper SurfaceSurface PropertiesProperties z SurfaceSurface porepore structurestructure isis importantimportant toto getget extrudateextrudate adhesionadhesion z OverallOverall structurestructure performanceperformance isis importanceimportance z ResistanceResistance toto penetrationpenetration byby liquidliquid oror gasgas z MeasuresMeasures thatthat tightentighten thethe basebase sheetsheet structurestructure cancan adverselyadversely affectaffect adhesionadhesion z MayMay requirerequire aa pretreatmentpretreatment RecycledRecycled FiberFiber BaseBase StockStock PotentialPotential ProblemsProblems andand ConcernsConcerns z DirtDirt z BladeBlade scratchesscratches andand streaksstreaks z ShadeShade variationvariation z SpotsSpots andand shinersshiners z ““BloomBloom upup”” ofof stickiesstickies underunder infraredinfrared dryersdryers z BrightnessBrightness reversionreversion and/orand/or yellowingyellowing z StrengthStrength lossloss PapermakingPapermaking AdditivesAdditives z MostMost extrusionextrusion coatedcoated gradesgrades areare usedused forfor packagingpackaging –– requiringrequiring strengthstrength z FillersFillers areare notnot commonlycommonly usedused z MeasuresMeasures toto improveimprove sheetsheet densitydensity z RefiningRefining toto increaseincrease densitydensity z SurfaceSurface sizingsizing z InternalInternal sizingsizing z CalenderCalender sizingsizing onon paperboardpaperboard WetWet EndEnd Additives/ChemistryAdditives/Chemistry BaseBase StockStock forfor ExtrusionExtrusion CoatingCoating zz FillersFillers seldomseldom usedused zz StarchStarch oror strengthstrength additivesadditives zz RetentionRetention aidsaids zz ““CycleCycle--upup”” potentialpotential withwith recycledrecycled fiber,fiber, especiallyespecially inin tightlytightly closedclosed systemssystems zz InternalInternal sizingsizing zz WetWet strengthstrength WetWet EndEnd OperationsOperations BaseBase StockStock forfor ExtrusionExtrusion CoatingCoating z CDCD profileprofile -- fromfrom thethe headboxheadbox oror formerformer z FormationFormation andand microcontourmicrocontour z FourdrinierFourdrinier boardboard -- DandyDandy rollroll -- TopTop formerformer z CylinderCylinder boardboard -- UniflowUniflow toptop linerliner vatvat PressingPressing zz MinimizeMinimize openopen drawsdraws forfor paperpaper zz EffectEffect onon bulkbulk andand stiffnessstiffness zz DoubleDouble sidedsided dewateringdewatering forfor paperpaper zz FlowFlow controlledcontrolled nipnip zz SplitSplit toptop feltfelt onon cylindercylinder machinesmachines zz FeltsFelts -- stratifiedstratified battbatt zz FeltFelt conditioningconditioning PaperPaper StructureStructure DryingDrying zz SlalomSlalom feltfelt runrun desirable,desirable, especiallyespecially forfor paperpaper zz ConventionalConventional cylinderscylinders -- WarmWarm upup dryerdryer temperaturestemperatures -- Picking/fiberPicking/fiber liftinglifting -- streaksstreaks zz YankeeYankee dryersdryers -- MachineMachine glazedglazed surfacesurface zz BreakerBreaker stacksstacks -- bulkbulk lossloss SurfaceSurface SizingSizing ChemicalsChemicals

z StarchStarch z FilmFilm formersformers otherother thanthan starchstarch -- CMCCMC -- PolyvinylPolyvinyl alcoholalcohol -- AlginateAlginate z OtherOther specialtyspecialty surfacesurface sizessizes z PigmentsPigments z LatexLatex andand otherother bindersbinders Size Press

Simultaneous application, metering and distribution TransferTransfer RollRoll CoatersCoaters z PremeterPremeter andand distributedistribute -- thenthen applyapply z SimilarSimilar toto aa printingprinting presspress

Gate Roll Coater Metering Size Press Calender Sizing • Pickup dependent on moisture profile • Crushes and compacts sheet • Reduces bulk and stiffness CalenderCalender BoxBox Calender Sizing Pickup Variables

Incoming Sheet •Speed •Moisture •Loading •Sizing •Material applied –Viscosity •Roughness –Solids •Formation –Temperature •Porosity Troubleshooting Calender Sizing

Non-uniform Foam application

Too tight Gluability film problem

Excessive No fiber tear ZDT

Soft Back side binder picking CalenderingCalendering TechniquesTechniques zzHardHard nipnip givesgives uniformuniform calipercaliper butbut cancan causecause localizedlocalized densitydensity variationsvariations andand mottlemottle zzSoftSoft nipnip givesgives uniformuniform densitydensity zzBothBoth improveimprove smoothnesssmoothness EffectsEffects ofof HardHard vs.vs. SoftSoft NipNip CalenderingCalendering PaperPaper andand BoardBoard CoatingCoating ForFor ExtrusionExtrusion CoatingCoating BaseBase StockStock z OpenOpen coatingcoating structurestructure isis desirabledesirable toto promotepromote extrudateextrudate adhesionadhesion z CoatingCoating pigmentspigments z Calcium carbonate z High aspect ratio clay z CoatingCoating bindersbinders z Latex z Acrylics and acetates z Biopolymer nanoparticle latex z Soy protein polymer PromotingPromoting AdhesionAdhesion andand DevelopingDeveloping ChemicalChemical ResistanceResistance z OxidationOxidation ofof thethe substratesubstrate z CoronaCorona treatmenttreatment z FlameFlame treatmenttreatment z ChemicalChemical primerprimer z SurfaceSurface modifiermodifier z increases energy z adds reactive sites z FacilitatesFacilitates extrudateextrudate wetwet outout TreatmentTreatment vs.vs. WetabilityWetability z TreatmentTreatment z OxidizesOxidizes thethe surfacesurface z makes chemical sites for bonding z BurnsBurns offoff contaminantscontaminants z ImprovesImproves wetwet outout ofof thethe primerprimer z WetabilityWetability z ImprovingImproving wetabilitywetability inin termsterms ofof contactcontact angleangle doesndoesn’’tt alwaysalways provideprovide adequateadequate adhesionadhesion PrimerPrimer onon PaperPaper BaseBase StockStock ChemicalChemical PrimersPrimers z SurfaceSurface modifiermodifier z increasesincreases energyenergy z addsadds reactivereactive sitessites z FacilitatesFacilitates extrudateextrudate wetwet outout z ProvidesProvides adhesionadhesion betweenbetween substratesubstrate andand extrudateextrudate z ContributesContributes toto thethe chemicalchemical resistanceresistance ofof aa structurestructure PrimersPrimers forfor PaperPaper z EthyleneEthylene AcrylicAcrylic AcidAcid z CrosslinkedCrosslinked PolyethyleniminePolyethylenimine z VinylVinyl Acetate/EthyleneAcetate/Ethylene z PolyesterPolyester z AmineAmine z MelamineMelamine z OthersOthers PigmentsPigments inin PrimerPrimer z AdditionAddition ofof pigmentpigment toto thethe primerprimer cancan improveimprove performanceperformance andand reducereduce costcost z KaolinKaolin clayclay pigmentspigments z HighHigh aspectaspect ratioratio clayclay opensopens porepore structurestructure z CalciumCalcium carbonatecarbonate z GroundGround calciumcalcium carbonatecarbonate z PrecipitatedPrecipitated calciumcalcium carbonatecarbonate -- aragonitearagonite PrimerPrimer ApplicationApplication MethodsMethods z Gravure,Gravure, Direct/ReverseDirect/Reverse z OffsetOffset Gravure,Gravure, Direct/ReverseDirect/Reverse z FlexographicFlexographic z SmoothSmooth TransferTransfer Roll,Roll, Direct/ReverseDirect/Reverse z WireWire WoundWound oror GroovedGrooved RodRod CoaterCoater SmoothSmooth RollRoll ApplicatorApplicator Transfer Roll Coaters

Hydrophilic Transfer Roll Coater - LAS Transfer Roll Coaters GravureGravure ApplicatorApplicator WithWith EnclosedEnclosed DoctorDoctor BladeBlade WIRE WOUND ROD WIRE WOUND WIRE WOUND WRAP ROD CONTROL ROD COATER ROLL STATIONARY ROD HOLDER APPLICATOR • Applies excess of ROLL COATING coating to the web PAN with an applicator roll • “Deckles” wipe the coating off the roll at the edges. • The substrate can be run with a dry edge for Figure 1 cleanliness. LOW SPEED AIR LOADED ROD COATER The main difference between the coaters shown in Figure 1 and 2 ROD occurs after the web leaves the ROD HOLDER applicator roll. AIR BLADDER Air-loaded rod coaters support the web with a backing roll.

Figure 2 GROOVED ROD TrendsTrends andand DevelopmentsDevelopments z SustainabilitySustainability focusfocus z WalWal--MartMart packagingpackaging scorecardscorecard z DesireDesire forfor paperpaper--basedbased packagingpackaging toto be:be: z RecyclableRecyclable z BiodegradableBiodegradable z ““PlasticPlastic CoatedCoated”” paperpaper andand boardboard consideredconsidered problematicproblematic z NewNew biodegradablebiodegradable resinsresins z PLAPLA RecyclabilityRecyclability ofof ExtrusionExtrusion CoatedCoated PaperPaper andand PaperboardPaperboard z DedicatedDedicated dede--polypoly systemssystems havehave beenbeen usedused forfor decadesdecades z WorkWork isis progressingprogressing towardtoward processingprocessing extrusionextrusion coatedcoated paperpaper productsproducts inin OCCOCC andand tissuetissue systemssystems z GlobalGlobal GreenGreen InitiativesInitiatives z StarbucksStarbucks cupcup programprogram z CORRCORR –– CoalitionCoalition forfor ResourceResource RecoveryRecovery RecyclabilityRecyclability ofof ExtrusionExtrusion CoatedCoated PaperPaper andand PaperboardPaperboard z NotNot justjust drivendriven byby environmentalenvironmental groupsgroups z OCCOCC supplysupply crisiscrisis z ChineseChinese millsmills havehave statestate--ofof--thethe--artart systemssystems andand cancan handlehandle singlesingle sideside extrusionextrusion coatedcoated wastewaste paperpaper OCC Shortage Due to Increased Chinese Demand Thousand of Metric Tons

50000 45000 40000 35000 30000 25000 20000 China OCC Demand 15000 10000 USA Containerboard 5000 0 2008 2009 2010 2011 2012 2013 2014 Data from RISI 15 Year Forecasts PotentialPotential NewNew SourcesSources ofof SecondarySecondary FiberFiber

PotentialPotential FiberFiber SourceSource 20072007 DiscardedDiscarded Tons*Tons* PaperPaper PlatesPlates andand CupsCups 1,310,0001,310,000 FoldingFolding CartonsCartons 4,020,0004,020,000 BagsBags andand SacksSacks 720,000720,000 TotalTotal 6,050,0006,050,000

* According to the EPA Municipal Solid Waste Report AlternativesAlternatives toto ExtrusionExtrusion CoatingCoating z RecyclableRecyclable barrierbarrier coatingscoatings z GainingGaining marketmarket acceptanceacceptance –– butbut progressprogress isis slowslow z InitialInitial successessuccesses areare inin replacementreplacement ofof waxedwaxed corrugatedcorrugated z WouldWould addadd ~1.5~1.5 millionmillion tons/yeartons/year ofof OCCOCC z DevelopmentDevelopment ofof aqueousaqueous dispersionsdispersions ofof z OlefinsOlefins z PLAPLA OutlookOutlook z MajorMajor consumerconsumer goodsgoods marketersmarketers havehave activeactive programsprograms toto replacereplace plasticplastic packagingpackaging withwith biodegradablebiodegradable oror recyclablerecyclable paperpaper basedbased packagingpackaging z ProgressProgress willwill bebe slowslow z ExtrusionExtrusion coatingcoating isis notnot likelylikely toto bebe replacedreplaced inin thethe shortshort oror mediummedium termterm z ContinuedContinued researchresearch onon recyclablerecyclable extrusionextrusion coatingcoating materialsmaterials ThankThank youyou forfor youryour attention!attention!