Paper 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 PAPERBOARD 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 COATED PAPER 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 Paper Mill...... 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: PULP & 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 Pulp and Paper Industry...... 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 Newsprint/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 PAPERMAKING
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 Paper Machine 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, Papers 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