Paper has a thousand faces

All paper types have one thing in common: they all have to match customer specifications while keeping costs to a minimum. This is exactly why we will tailor your solution to your requirements together with you, the customer.

Brain: product properties to increase competitiveness for joint planning and development. The gain in quality in paper creates new approaches for productivity increases.

Pigments: individual custom solutions allow a high degree of freedom for fillers and paint pigments. Example: more flexibility in your product range through freely definable parameters such as whiteness, structure, texture or abrasion properties.

And after that? We will also continue our support in the constant development of your paper range after the development phase.

TiO2-savings in production of laminated paper by using a high functional filler

Introduction

Laminated paper consists of TiO2 up to 40 % Ma-% and more. Savings in TiO2 resulting in decreasing costs in production while keeping the very high quality of this type of paper is important for all producers of laminated paper. A new high functional filler is used to find out the advantages when used in laminated paper.

Project partner

Institute, Pilotcustomer

Methods

Rapid Koethen, 40 % ash content

Functional Filler

VP TRF_1, Suspension, 2, 4 and 8 % in exchange with TiO2

Coating

Melamin and acrylat resin

Summary

  • The new high functional filler was easily brought into the paper making process
  • The parameter of the base paper have been equal or better, for example: TiO2-Retention, Brightness, Tensile strength
  • Also the quality of the paper after lamination was equal or even better, for example: Opacity, Brightness, Stability against Xenon light
  • 8 Ma-% of the previously used TiO2 (100 Ma-%) have been replaced by the high functional filler while keeping the quality of the paper after lamination
Structured calcined kaolin as a functional coating pigment for thermosensitive paper

Description of the tests

Structured calcined kaolin as a thermo-insulating layer with increased technical performance

Product

Thermosensitive Paper

Precoat-slurry

Solid content: 23 %, 100-150 mPas

Weight of Coating

7,2 m2/g, Thermo-insulation

Weight of Thermocoat

4,8 m2/g, Thermo-coating

Testtype

Lab- and Productiontest

Productionsize

6 rolls

Test Operation

Production plant at customer‘s

Comparison: New Development - Structured Kaolin 1 + 2 / Standard, State of the art

 

Results of the Production Test

  • Improved image density at low energy input
  • Very good long time stability
  • Very good runability
  • High solid content of the pigment slurry
  • Reduced costs for the paper producer and the enduser
Reducing TiO2 Consumption in Laminated Paper

Test formulation

  • Short fibers Eukalyptus Cania
  • Long fibers ZPR Rosenthal
  • TiO2
  • Additiv
  • Nadavin (4 wt%)
  • NaHCO3

Ash content

30-31 wt%

Paper formation

Paper formation was carried out on a laboratory scale following DIN 54358.

Lamination

On furniture chipboard, one test paper and one reference on each board.

 

 

The content of TiO2 and functional filler given in the diagrams has been determined from chemical analysis of the raw paper (X-Ray fluorescence).

 

 

Benefits of the new developed solution

Enhancement of opacity (raw paper) and brightness of the laminated paper as an indicator for opacity.

Development of Paper with a Volume Index > 1,6 cm3/g

Background

Development of paper with a volume index > 1,6 cm3/g

Requirements

  • volume index > 1,6 cm3
  • elastic paper structure
  • improved calandering characteristics
  • lower loss of volume by after calandering
  • homogeneous surface, improved gloss

Technical data of the production trial

Paper Bulky Paper, Offset
Weight 50g/m2
Scale of Production 6t
Cellulose Cellulose 500 SR
Content of Filler 20 % related to Cellulose
Retention Persol 63-0,01 %, related to Cellulose
Optical Additive Heliofor, 0,1 Ma-% related to Cellulose
Volume Index Standardpaper 1,50 - 1,55 cm3/

 

Increasing the Volume Index in Trials 1 to 6

Results

  • The volume index of the standard paper could be highly increased
  • The rate of improvement was about 25 % resulting in a volume index of 1,9 cm3/g
  • Also the loss of volume by calandering was lower than the standard paper
Development of paper with increased Opacity

Descripton of the Pilotcoatertest

  • Papertyp: Offset, pre- and topcoated
  • Coating: precoat only
  • Mineral Component 1
  • Mineral Component 2
  • Mineral Component 3
  • Coating Mixture, solids > 65 % solids
  • pH-value 8,3-8,6
  • Coater Speed 1300 m/min
  • Coating weight: 12 g/m2
  • Basepaper 56 g/m2
  • Topcoating Mixture delivered by customer, 12 g/m2
  • Calander 300 m/min, 80 °C, 110-130 N/mm
  • Results in No.1 = Actual Paper Quality
  • Results in No. 2-4 = Optimized Paper Quality

 

 

 

Improved print quality of Inkjet paper using new silicates for paper coating

Introduction

High quality pigments for Inkjet coating are showing acceptablereological behavior, high water- and solventabsorption, a very good print image and at least an excellent over all print quality in all printer types.

Project Partner

Institute and own R+D

Methods

Standard process for Inkjet coating and testing

Functional additiv

VP MGS_1, Suspension, 20 %

Coating

Standardrecipe: 80 % Sipernat, 20 % Aerosil
Testrecipe: 50 % Sipernat, 10 % Aerosil, 40 % VP MGS_1

Summary

  • The additives can be easily worked into the coating system
  • Viscosity and solids of the coating are good
  • Almost no dilatant behaviour
  • Visual print quality at Epson C 62 is good
  • Image denisty is better or equal
  • Very good over all print quality
D 95: Functional Pigment for Inkjet Coating

Objectives

  • Introduction of D 95 as an alternative pigment for inkjet coating
  • Use of D 95 in high end applications
  • Extending parts of pyrogenic and precipitated silica
  • Trying to keep the very high level of paper quality
  • High slurry solids for paper coating
  • Very interesting cost / performance for paper producer and end user

Inkjet printer and classification

  • Inkjet printer and classification
  • Epson Stylus C62
  • Qualiyt: Text and pictures
  • Papertype: 360 dpi Ink Jet Paper

 

Results

  • D 95 was easily dispersable in cationic slurry
  • High slurry solids for paper coating (up to 33 Ma-%)
  • It was possible to reduce the amount of pyrogenic and precipitated silica
  • The quality of the paper was nearly at the same level as the benchmark
  • The recipes have shown very good rheology, even at higher coating speed
  • Almost no difference in bleeding
  • Slightly higher matting effect with increasing amount of D 95
  • The use of D 95 resulted in prints with high optical density
  • All Inkjet prints had extremely good results with respect to wicking
Functional additives for the production of paper with reduced flammability

Introduction

For special applications, for example in indoor construction or decorative use new light weight products are used. More and more paper based raw materials are taken for example in furniture products. Because of the paper based core an increased effort is necessary to take care about the flammability. The use of functional additives during the paper making process contributes to reduce the flammability of the final light weight product.

Project partner

Institute and Pilotcustomer

Methode

Standard methods for paper processing and testing, Rapid Koethen

Functional Additiv

VP FSF_1_ G and FSF_1_D

Summary

  • The additiv suspension can easily be brought into the paper making process
  • Despite increased filler, tensile strength was almost on the same quality
  • Flammability was reduced the more functional additive was brought into the paper
Improved smoke depression in cigarette paper by new inorganic additives

Introduction

For smoke depression in cigarette papers specific mineral fillers are used, for example Mg(OH)2. In pretests a new developed inorganic additiv is compared to standard filler material.

Project partner

Institute and Pilotcustomer

Methods

Standard methods for paper processing, coating and testing, like DIN

Functional Additiv

VP NMH_1, Suspension

Summary

  • The additiv suspension can easily be brought into the paper making process
  • The addition of the new inorganic additiv resulted in an improved paper quality
  • The amount of the new additiv can decreade In comparison to the standard filler