Conference and Trade Show (PaperCon 2016)

Cincinnati, Ohio, USA 15 - 18 May 2016

Volume 1 of 3

ISBN: 978-1-5108-3119-3 Printed from e-media with permission by:

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Curran Associates, Inc. 57 Morehouse Lane Red Hook, NY 12571 USA Phone: 845-758-0400 Fax: 845-758-2633 Email: [email protected] Web: www.proceedings.com TABLE OF CONTENTS

VOLUME 1

C1 COATING OPENING SESSION AND KEYNOTE

Paper & Packaging Innovation...... 1 Ed Zumbiel

C2 MARKET TRENDS IN PACKAGING GRADE TRANSFORMATIONS

Retail Ready Packaging ...... 20 Charles P. Klass

Market Trends in Packaging...... 33 Dan Malenke

Trends Lightweight Paper Based Packaging...... 45 Robert Pederzani

C3 APPLICATIONS

Post Print Laser Marking: A Solution to the Challenge of 100% Calcium Carbonate Coating When Using CO2 Lasers...... 54 Roger Bollstroem, Patrick Gane

Ultrafine Cellulose Particles for Coating ...... 62 Sascha Galic

The Effect of Paperboard Coating Treatments on Polyethylene Adhesion During Extrusion Coating ...... 71 Don Ventresca, Kelly Frey, Greg Welsch

C4 SUSTAINABLE PACKAGING

Pigmented Formulations Containing Biobased Nanoparticle Binders for Curtain Coating Applications; Part 1: Rheological Study ...... 92 Ting Chen, Margaret Joyce, Paul D. Fleming, Do Ik Lee, Steven Bloembergen

Pigmented Formulations Containing Biobased Nanoparticle Binders for Curtain Coating Applications; Part 2: Curtain Stability Analysis...... 122 Ting Chen, Margaret Joyce, Paul D. Fleming, Do Ik Lee, Steven Bloembergen

Conversations Around Environmental and Societal Drivers for Materials ...... 146 Ramani Narayan

C5 ANALYSIS

Analysis of Microscope Images of Coating Layers That Contain Tagged Starch and Latex ...... 163 Emilia Golebiowska, Douglas Bousfield, William Gramlich

New Method to Determine Pigment Friability: Example SPCC...... 175 Cathy Ridgway, Patrick Gane

Improved Discrete Element Method Model to Predict Coating Layer Mechanical Properties ...... 186 Dan Varney, Douglas Bousfield

C6 SUCCESS STORIES

Air Floatation Dryer Optimization...... 207 Don Cesario

Fast Track Coating Head Conversions at a North American Coated ...... 220 Jeff Gorges

Cartones Ponderosa PM1: Curtain Coater Installation...... 225 Pam Hynnek

Calendering Control by Roll Hardness Measurement...... 236 Jyrki Laari

C8 FLEXO PRINTABILITY IN PACKAGING

Paper Without Ink is Silent, Ink Without Paper is…Messy...... 241 James Ford

Flexo Printability: Press Technologies...... 251 Jean Jackson

Flexo Printability in Packaging...... 265 Doug Weiss

C9 RHEOLOGY

Rheology: A Tutorial on the Basics ...... 279 Tony Lyons, Rajan Iyer

Review of Coating Thickening Mechanisms...... 300 John Roper

The Influence of Pigment Concentration, Particle Size Distribution, and Aspect Ratio on Rheology ...... 314 Lisa Weeks, Doug Bousfield, Anthony Lyons

M3 – YOUNG PROFESSIONALS PRESENT RECRUITING, RETENTION, AND REAL ISSUES FOR YPS IN THE WORKPLACE

How to Attract More Students to the Paper Industry...... 329 Roland Gong, Karyn Biasca

Positioning for Success...... 347 Jonathan Kerr

Leading From Within ...... 359 Bill Sleeper

M5 – EMBRACING CHANGE IS SUSTAINABILITY

Improving Without Capital – Releasing the Untapped Potential ...... 374 Erin Saueracker

M8 – MEETING THE CHALLENGE OF CHANGE THROUGH THE WORKFORCE DEVELOPMENT

Aligning Workforce Development with the Business ...... 381 Patti Phillips

Suppliers Share Interest in Mill Workforce Development ...... 387 Daryl Wells

M11 – DIGITAL REVOLUTION: & PAPER MILL OF THE FUTURE – INDUSTRY 4.0 – FUTURE IT OF THE MILL

Prediction and Simulation Analysis at Paper Mills ...... 394 Timo Arra

PIMA IT Symposium: Future IT of P&P Mill...... 403 Mike Harwood, Carl-Fredrik Hammarqvist, Christophe Deslandes, Timo Arra

Cloud Computing for Pulp and Paper Mills ...... 405 Christophe Deslandes

Future at Paper Mill...... 413 Carl-Fredrik Hammarqvist

M12 – DIGITAL REVOLUTION: PULP & PAPER MILL OF THE FUTURE – SMART AND PREDICTIVE USE OF DATA AT MILLS

Big Data Application to Combine the Value Chain Data to Knowledge...... 422 Matti Hakkinen, Mika Suojarvi, Jari Suihkonen, Michael Gee, Savcor Oy

Let's Put it on Paper: Data Strategies Towards Operational Excellence...... 427 Mariana Sandin

Solving Big Data Problems in a Paper Mill ...... 445 Rick Smith

Virtual Onsite Presence – Improving Access to Remote Experts ...... 457 Michael Von Grumbkow, Jon Blankenship

O1 – MAINTENANCE & RELIABILITY

Job Plans for a Reliable Future: Communicating the Essentials...... 468 Dan Moss

O2 – MAINTENANCE & RELIABILITY

Basics of Self-Supported Rotary Joint Installation on Steam-Heated Paper Dryers...... 481 Alan Ives, Ken Lahrke

Reactive to Proactive & the Application of Strategic Reliability Principles...... 497 Jay Shellogg

O3 – MAINTENANCE & RELIABILITY

Motors, Pumps, & Fans. It’s the Little Things that Make a Difference! ...... 507 Robert Forstrom

Overlooking Rockers and Rocker Plates Can Lead to Dryer Component Failures ...... 534 Myron Smith

PA1 – SUSTAINABILITY – FIBER AND FILLER

Improved Machine Efficiency Through Addition of GCC Filler in Recycled Liner and Medium...... 540 Lars Andersson

Enhancing Sustainability in Paper and Board Products ...... 552 Ekhard Beuleke

Low Energy CTMP in Strong and Bulky Paperboard Plies...... 556 Gunilla Pettersson

PA2 – PAPERBOARD SUSTAINABILITY - ADDITIVES

The Benefits of Sustainability: A Mill's Experience ...... 565 Allen Bowdler, Julia Hulbert, Amy Sand, Jack Block, Dan Anderson

Odor in Recycled Packaging Grades. Identifying the Cause and Finding the Solution...... 569 David R. Jones

The Use of a New, On-site-generated Strength and Productivity Additive in Brown Grades Made with Recycled Fibers ...... 574 Jerry Sajbel

PA3 – SIZING INSIDE AND OUT

Prediction of Starch Penetration During Sizing and Drying...... 578 Douglas Bousfield

Optimizing Printing Primers on the Size Press...... 599 Talia Collins

A Novel ASA Polymer Emulsifier for Improved Sizing Efficiency...... 607 William Johnson, Bradley Benz

Continuous Starch Enzyme Conversion ...... 618 Erik Takens, Susan Sargeant

PA4 – IMPROVING PRODUCTIVITY USING PROCESS CHEMICALS

Don't Stop Believing...or You CAN Really Get What You Want! ...... 631 Janie Lasik, Allen Bowdler

Tackling Complex Sheet Production Efficiency and Effluent Quality Issues Using Advanced Bioanalytical Strategies ...... 638 Liliya Lund, Xuejun Wang, Laura Rice, Elisa Luth

New Commercial Process for Production of Mineral/ Microfibrillated Cellulose Composite Materials Exhibits Great Flexibility...... 650 David Skuse

PA5 – WATER QUALITY MANAGEMENT

Innovating Water Disinfection Treatment Programs in the ...... 666 Andrew Boal

Multiparameter Analyzers for Efficient Monitoring of Pulp and Paper Industrial Waters ...... 674 Lori Carey

Fresh Water Quality – Quality Requirements and Treatment Options...... 675 David Cifuentes

PA7 – MICRO/NANO CELLULOSE

Cellulose Filaments: Discovery by FPInnovations of a Novel Strengthening Agent ...... 683 Xujun Hua, Makhlouf Laleg, Thomas Owston

Physical Properties of Attritor Pulp-containing Handsheets ...... 695 David Knox, Peter Hart, H. J. Moynihan, N. M. Kilgore

Phosphorylated Nanofibrillated Cellulose: Production and Properties...... 706 Ali Naderi, Tom Lindstrom, Christoph F. Weise, Goran Flodberg, Jonas Sundstrom, Kristina Junel, Johan Erlandsson, Annmarie Runebjork

PA8 – ADDITIVE MIXING TECHNOLOGIES

Feeding Point and Mixing Power in Simultaneous Feeding of Filler and Starch ...... 723 Emmi Kallio, Jari Kayhko

Non-spinning, Fluidizing Flash Mixing Reactor for Synthetic Fibers, Nano- and Micro Fibers and Agressive Chemicals for Board, Paper and Tissue Production ...... 734 Jouni Matula

VOLUME 2

There's Always Room for Improvement - Flow Solutions in the Coatings and Additives Area ...... 743 Vincent Miller, Jeff Wilmer

PF1 – DRIER WEB

Estimating Limits of Wet Pressing on Paper Machines...... 751 David McDonald, Richard Kerekes

Influence on Sheet Dewatering by Structural Differences in Forming Fabrics ...... 767 Bjorn Sjostrand, Christophe Barbier, Lars Nilsson

Drier Paper Webs Through Research and Innovation ...... 777 Jun Xu, Gregory Pittman, Chuck Hunter, Beth Cormier, Fred Hanson, David Turpin

PF2 – CHALLENGES FOR MILLS CONVERTING TO LINERBOARD GRADES

Using Advanced Instrumentation for a Successful Gap Former Conversion from /LWC to Corrugating Medium...... 789 Frank Cunnane

Converting a Newsprint / P&W Grade Machine to Linerboard Grades….Considerations from an Approach Flow / Stock Preparation Standpoint ...... 799 Richard Turnbull

PF3 – IMAGING TECHNOLOGY FOR

New Possibilities for Comprehensive On-line Web Monitoring and Web Inspection to Improve Papermaking Efficiency and Paper Quality ...... 815 Kari Hilden

Real-time ROI Morphometrics in High Quality Web Imaging...... 834 Tommi Huotilainen, Myron Laster, Seppo Riikonen

On-line Topography Analysis by Photometric Stereo Method – New Tools for Paper and Board Makers ...... 855 Seyhan Nuyan, Ismo Makinen

Advanced Image Based Measurement Techniques for Analysis of Process Variations ...... 871 Catherine Ostlund, Hannes Vomhoff, Hans Christiansson

PF4 – FRONTIERS IN FORMING

Aqua Layering Headbox and Furnish Optimization: A Tool for Process Flexibility and Quality Improvement...... 879 Juan Cecchini, Hannu Turpeinen

The Effect of Long Fibers in Sheet Properties in Foam Forming...... 894 Antti Koponen, Katariina Torvinen, Ari Jasberg, Harri Kiiskinen

PF5 – NEW SHEET MEASUREMENTS TECHNOLOGY

Characterization of Paperboard Formation using Soft X-radiography and Image Analysis...... 905 Hossein Abedsoltan, Gary Wood, D. Steven Keller

On-line Tissue Softness Measurement – A Useful Addition to Tissue Automation Concept...... 917 Tommi Loyttyniemi, Seyhan Nuyan, Marko Toskala

LED Based Color Sensor for Paper Web Measurement and Control...... 924 Michael O'Hora, Hakan Hjalmers

PF6 – NEW PROCESS CONTROL TECHNOLOGY

Simplified Model Predictive MD Control of Paper Machines...... 929 Michael Forbes, Cristian Gheorghe, Joyce Choi, Pezhman Nafissi

An Update on Consistency Transmitter Measurement Technology & Process Considerations ...... 942 Mike Hendricks

Optimal Operation of a QCS Scanner in a Based on the Information of QCS and WIS Measurements ...... 952 Jukka-Pekka Raunio, Risto Ritala

PF7 – PERFORMANCE INDICES AND BENCHMARKING

On-line Process Analytics for Improved Process Control ...... 963 Timothy Deschaines

Visualization of Process, Control and Performance Information...... 965 Calvin Fu, Seyhan Nuyan, Kevin Rohr

Innovations in Plant-Wide Monitoring, Diagnostics & Optimization...... 973 Robert C. Rice

PF8 – FIBER SUSPENSION DYNAMICS

The Flocculation Response of a Dual Component Retention System Subject to Different Mixing Conditions...... 987 Paul Krochak, Bo Norman, Lennart Hermansson

Flow Behavior of Refined Wood Fibre Suspensions...... 995 Abbas Nikbakht, James Olson, Mark Martinez

PF9 – APPLICATIONS OF CFD IN PAPERMAKING

Successful CFD Projects: An Overview of Successfull Product Development Using Integrated Fluid Modeling and Experiments ...... 1008 John J. Egan, Christopher L. Demler

Turbulent Stress Measurements of Fibre Suspensions in a Straight Pipe with MRV...... 1024 Jordan Mackenzie, Agne Swerin, Fredrik Lundell, Daniel Soderbert

Computer Simulations of Wet Press at a Flexible Individual Fiber Level...... 1032 Yihsin Tang, Dewei Qi

PM1 – WHO IS GOING TO DO?

Who Is Going To Do? Kickoff & Roundtable ...... 1054 Jeff Reese

PM2 – WHO IS GOING TO DO? PANEL DISCUSSION

Paper Optimization Manager, Kapstone Paper...... 1065 Brad Bowman

Who's Gonna Do?...... 1067 William Cone

Just Get it Done! ...... 1070 Gary Neyer

Who's Gonna Do? (or How Are We Going to Do?)...... 1072 Steve Pearson

Who's Going to Do? Getting Things Done...... 1076 Steve Smith

PM3 – WHO IS GOING TO TRAIN? PANEL DISCUSSION

How Much will Mentoring Impact the Future of Training? ...... 1081 Lesley Cook

Who You Could Turn To For Continuing Education Training...... 1083 Mary Beth Cornell

What is Needed and How Will the Training be Done...... 1089 Mike Kocurek

Bridging the Knowledge-to-Skills Gap Using the Humble PC...... 1104 David Leigh

Developing Leaders for the Future of Our Industry ...... 1112 Chris Luettgen

Innovative Technology Training Strategy for the Pulp, and Chemical Process Industries ...... 1118 Christie Prout

PM4 – WHO IS GOING TO DO THE REBUILDS?

Grade Conversion from Graphic to Packaging Paper, A Successful Case Study ...... 1138 Martin Jauch

How to Effectively Improve Paper Quality? - A Modern Hydraulic Headbox as a Cost Effective Way to Enhance PM Performance...... 1144 Maja Mejsner

Reducing the Risks and Raising the Roi in Conversions of Groundwood and Freesheet Machines to Packaging ...... 1148 Daryl Wells, Dave Burton

PM5 – WHO IS GOING TO MANAGE OUR PROJECTS?

Equipment Installations with Virtual Process Integration: A New Method for Reducing Downtime and Eliminating Change Orders ...... 1160 Dan Goymerac, Dan Bayer, Tonya Dittman

A Case for Integrated Front-End Engineering and Design ...... 1175 Kenneth Carrillo

PM6 – WHO IS GOING TO COME UP WITH BETTER MOUSETRAPS?

Optimizing Your Machine Efficiency Through New Seal Strip Technology...... 1183 Wyatt Boyett

A New Family of Forming Structures Provide Higher Dewatering, Planar Sheet Surface, and Lower Drag Loads ...... 1188 Frank Cunnane

Optimizing Waste Water Treatment in Paper Mill Lagoons ...... 1197 Richard Grenville

PM8 – SUCCESS STORIES

Successful Shoe Press Installation at Greif's Riverville, Virginia Mill...... 1215 Robby Compton, David Deese, Mitch Heishman

Optical Process Monitoring with Paper Defect Detection Cameras in Forming and Press Sections on a Gypsum Board Facing Paper Machine...... 1222 Weig Karton

Eye Opening Operating Results of Flash Mixing Reactor for Efficient Use of Wet End Additives ...... 1234 Jussi Matula

Mechanical Seal Selection, Reliability, and Optimization ...... 1244 Dick Reese

Cartones Ponderosa - Managing Change to Maintain Market Lead ...... 1260 Rex Robertson

Detailed Project Planning Helps American Eagle Paper Mills Achieve Impressive Results ...... 1268 Andrew Symons, Steve Pepin

PM9 – WHAT DO I DO WITH ALL THIS DATA?

Capture the Benefits of the 'Stable and Capable Moments'...... 1270 James Black

Who is Going to Optimize the Performance of Paper Machine Clothing?...... 1279 Marcel Lensvelt

Utilization of Data for Diagnostics & Processes Transparency...... 1284 Mika Suojarvi

PM10 – WHO IS GOING TO HELP US OPTIMIZE OUR SYSTEMS?

Optimizing Recycled Paperboard Production - Former Section ...... 1288 Blake Hender

Pumping Systems Optimization...... 1299 William Livoti

Reducing Fresh Water Usage – Disc Filter Save-all Optimization ...... 1314 Nicolas Reinke

PM11 – WHO CAN HELP US DO?

Help OEMs Help You: Getting Better Designs for Automation and Reliability from Your Suppliers...... 1318 Marie Getsug

If You Don't Control Your Destiny Someone Else Will ...... 1337 Janie Lasik

A Directional Approach to Tasks On the Paper Machine ...... 1343 Michael Mackett

PM12 – WHO IS GOING TO HELP IMPROVE PAPER PERFORMANCE

Non-destructive Determination of Key Pulp & Paper Process Parameters...... 1356 Timothy Deschaines

New Test Method for Predicting Crushing Elasticity in Medium Fluting. a More Relevant Than Total Fluting Test Methods Like Cmt/concora ...... 1358 Thomas Furst

Impact of Kraft Hardwood and Softwood Pulp Viscosity on Paper Properties...... 1370 Humphrey Moynihan

PM13 – WHO IS GOING TO DO? WRAP UP AND ROUNDTABLE

Track Wrap-up...... 1380 Jeff Reese

RPTA1 – HOT TOPICS

Offsetting the Costs of Recycled Fiber Wastes...... 1419 Paul Fowler

Food Packaging Safety & Mineral Oils Migration ...... 1429 George Fuchs

Developments in Mineral Oil Hydrocarbons Regulations in Europe...... 1437 Paul Noe

RPTA2 – ADVANCES IN PRESSING TECHNOLOGY

Improved Uhle Box Dewatering...... 1445 Farhad Fereydoonzad

Improved Performance with Unique Predictive Analytics...... 1456 Eric Gustafson

High Performance Pressing on Recycled Paperboard ...... 1468 Rick Phillips

VOLUME 3

RPTA3 – IMPROVING PULPER OPERATIONS

Hydraflow Continuous Detrashing Systems...... 1479 Christopher L. Demler

Opportunities and Approaches for Improving Broke Pulping ...... 1492 Hanna Jokinen

Pulper Upgrades: Process Considerations and Performance Expectations...... 1504 William Pitman

Improving Pulper Operations: Low Energy Recycled Pulp Production...... 1531 Greg Sleeper

RPTA4 – IMPROVING DRYER PERFORMANCE

Managing Siphon Life in Small Diameter Dryers: 48" Diameter and Smaller...... 1546 Rick Hall

Overview Of Steam System Optimization ...... 1556 Mike Soucy

Paper Machine Dryer Section Troubleshooting...... 1581 Lawrence Yane

T1

The Profit from Monitoring and Improving Your Process Control...... 1598 Hank Brittain

T4

Alum and Rosin Based Sizing ...... 1641 John Leckey

T6

Low Consistency Refining: 1 Day Training...... 1670 Arvind M. Singhal

T8

Printing and Printability...... 1706 N/A

T9

Introduction to Pigment Coated Paper and Paperboard Grades, Processes and Materials...... 1805 Charles P. Klass

TF1 – KEYNOTE SESSION

T&T Observations...... 1844 Rod Fisher

TF2 – ALTERNATIVE FIBERS

New Kneader-Based Non-wood Pulping System for Tissue Fiber Production...... 1867 Hiroki Nanko

High-yield Pulp in Tissue and Towel...... 1882 Zhirun Yuan, Jimmy Jong, Stephan Lariviere

A Review of Non-wood Fibres and Their Applications in Tissue ...... 1894 Xuejun Zou, Hongbin Liu

TF3 – UNDERSTANDING AND MEASURING TISSUE SOFTNESS – PANEL DISCUSSION

Understanding and Measuring Tissue Softness ...... 1905 Jessica Carette

TSA (Tissue Softness Analyzer) – Objective Measurement of Tissue Softness ...... 1916 Alexander Gruner

The Complexity of Understanding and Measuring Tissue Softness ...... 1922 Ward Ostendorf, Jeff Sheehan, Monica Ho-Kleinwaechter, Dave Loebker

Measuring Paper Softness-Leveraging Sensory Hand Feel Panels in R&D and Manufacturing ...... 1927 Nicolette Vanderklaauw, Andrea Cummings, Shuo Wang, Michelle Lyons

TF4 – PROCESS CONTROL FOR TISSUE

Predictive Analytics, Dynamic Suction Roll/Yankee Nip Monitoring and Innovative Cover Venting Deliver Significant Energy Savings and Improved Efficiency on Modern Tissue Machines ...... 1933 Michael Ciccone

New On-Machine Instrumentation Provides Novel Process Control and Cost Saving Benefits ...... 1940 Frank Cunnane

Advanced Vibration Tool for Crepe Blade Monitoring ...... 1955 Timothy Patterson, Donald Schultz

TF5 – STRUCTURED SHEET INNOVATIONS

TAD Structured Sheet for Ultra-Premium Quality...... 1967 Soren Eriksson

Measuring the Compressive Response of Embossed and TAD Features in Paper Towels ...... 1986 D. Steven Keller, Guizhou Wang

Evaluation of the Compressibility of Kitchen Towels ...... 1998 Hannes Vomhoff, Farnaz Farahani, Mikael Bouveng, Catherine Ostlund

TF6 – OPERATING EFFICIENCY/ENERGY SAVINGS

Transfer Efficiency Study of Spray Systems in High Web Speed Additives ...... 2010 Ben Drummond, Kathleen Brown, Rudi Schick

How to Minimize Energy and Increase Cleanliness in Tissue Plants: Part 2 ...... 2022 Marco Pescantin

Results from Paper Machine Energy Audits in Wisconsin Tissue Mills...... 2041 Dick Reese

Energy Optimzation of the Yankee Dryer Hood...... 2073 Alfredo Sarli

TF7 – TISSUE PROCESS OPTIMIZATION

Improving Tissue & Converting Machine Efficiency by Detecting Defects and Reducing Breaks ...... 2083 Pete Angle

Paradigm Shift: Improved Dry Strength in Bath Tissue without Affecting Softness...... 2093 Joseph Mahoney, J. Todd Sarraf

Creping Operating Window-Adhesive and Modifier Contributions...... 2105 Timothy Patterson

Advanced Fiber Management for Improved Tissue Machine Productivity and Quality...... 2115 Jeff Peters

TF9 – PRACTICAL SOLUTIONS FOR TISSUE

New Regulatory Standards and Practical Solutions for Combustible Dust: A Comprehensive Review...... 2125 W. Brad Carr

Liquid Ring Vacuum Pump Energy Savings...... 2134 Andy Smiltneek

The Inherent Non-Homogeneous Nature of Cast Iron and its Effect on Creping...... 2147 John Holton

TF10 – STEEL YANKEE PANEL DISCUSSION

Steel Yankees General Topics ...... 2166 Marco Brujas

Steel Yankee Dryers: The Next Step in their Evolution...... 2173 Clive Butler

Can You Identify These Materials Used to Manufacture Yankee Dryers? ...... 2178 Ronald Clarke

Steel Yankee Dryers and Tissue Making ...... 2192 Magnus Hogman

Steel Yankee Logistics...... 2199 Michael Janosch

Author Index