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contents
DISSOLVING PULP
10
OPINION
MAINTENANCE
19
DEPARTMENTS
BACK TO BASICS
BLEACHING
25
38 SHOWCASE
28
32
39 CLASSIFIED
39 ADVERTISERS INDEX
COATING
34
WHATS NEW
Greg Rudder, Steven Sachoff, Bryan Smith, Irina Van den Neste, COPYRIGHT 2014, For Classified, reprints and List rentals, please contact
by RISI, Inc.
Daniela Wortmann, Rita Yao, Jessica Zimbalatti All rights reserved. Monica Zaskiewicz - Account Executive
Tel: +1.770.373.3002 - mzaskiewicz@risi.com
Publisher.................................................................................................. Misty Belser Published monthly.
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Sussex, WI
Vice President, Operations....................................................................Rich Spinale
that each of you are special and unique. The letter has gone viral
around the world, and the extent it trended on Twitter will almost
certainly result in more of the same in education circles. Nothing
really beats a good old-fashioned personal letter.
These stories seem like good news for the printings & writings
industry, but perhaps dont order that 1 million tonne/yr new
machine just yet.
Fantastic response to the PPI Awards
This editorial comes to you this month from a hotel in Tampere,
Finland, where coincidently my room overlooks Mets Boards
Tako mill, right in the middle of the city. It is amazing actually,
because I can see a tiny little bit of steam coming out of some
vents at the top of the mill, but can hear hardly as sound, just a low
rumble from the PMs. Which reminds me that as I write this piece
this month, our highly esteemed judges for the PPI Awards are all
vigorously pouring over the hundreds of entries that have come in
this year.
We have been truly delighted with the response we have had
and the awards, now in their sixth year, have truly come of age. I
remember when we first launched it was like pulling teeth trying to
get companies to enter, now all we need is a reminder and a bit of
ushering.
The most popular categories, and the area where the judges
are undoubtedly going to have their work cut out are, Business
Strategy, Environmental Strategy, Sustainable Packaging and Speciality Papers. Both the quality and the quantity in those categories
this year was very impressive.
It does seem as if producers all around the world are embracing the PPI Awards, for those of you who have entered, it will be
really great to see you and your colleagues in Boston in October to
celebrate.
Good luck to all our contestants for the PPI Awards 2014!
c
.mia
www
.info
International Exhibition
of Paper Industry
At MIAC 2014 you will find machinery, plants and
equipment for the production and for the converting
of paper and paperboard. In Europe, Lucca is the
number one spot for tissue production and Italy is
also one of the leader countries in the corrugated
cardboard sector. The Visitors of MIAC 2014 will
be able to meet, during the 3 days of Exhibition, the
leader suppliers of the Paper Industry sector which
will present the latest developments in machines,
systems and avant-garde solutions.
15 16 17
OCTOBER 2014
LUCCA - ITALY
www.papnews.com
MIAC is organized by: EDINOVA Srl - Via Pordenone 13 - 20132 Milan - Italy
phone +39 02.2158021 - fax +39 02.2140961 - miac@miac.info - www.miac.info
w h a t s n e w
WHATS NEW
N e w s s h o r t s f r o m t h e p u l p a n d pa p e r w o r l d
10
w h a t s n e w
WHATS NEW
as feedstock to make fossil-free and greener everyday products. At the
heart of it are advanced biorefineries and innovative technologies that
will convert renewable resources into sustainable bio-based chemicals,
materials and fuels.
Organised in five value chains - that range from primary production to
consumer markets - the BBI will help fill the innovation gap between
technology development and commercialisation, sustainably realising
the potential of bio-based industries in Europe.
P R O J E C T S & O P E R AT I O N S
Arauco to convert BSK/BHK Valdivia
mill to dissolving pulp
Chilean group Arauco has plans to convert its 550,000-tonne/yr Valdivia
bleached and hardwood kraft pulp mill to dissolving pulp (DP) by 2017.
The project is estimated to cost $180 million (Euro 133 million) and
would allow the company to produce both paper grade and dissolving pulp at the same mill, according to market conditions, said the
companys marketing & sales director, Ricardo Strauszer.
The first step for the change was taken this week, when Arauco filled
with Chiles environmental authorities the request for industrial modifications. We expect that the permission will be granted by the end of
the year and then we can move on with the equipment purchase, so the
conversion is expected to be completed in the first quarter of 2017,
the executive stated.
After the revamp, the mill will have capacity to produce about 500,000
tonnes/yr of viscose DP. Within the mill learning curve, Arauco also
expects to produce high quality DP for the specialty markets.
calendar
SEPTEMBER
17-19: TAPPI Bioenergy &
Bioproducts Conference -
Santa Maria
Brazilian paper producer Santa Maria Cia de Papel
e Celulose has finalized its 64,260-tonne/yr PM 2
revamp project, according to Voith Paper. PM 2 is
installed at Santa Marias 99,960-tonne/yr paper
mill located at the city of Guarapuava, Paran state,
southern Brazil.
OCTOBER
7-9: ABTCP 47th Pulp & Paper
International Congress &
Exhibition Transamerica Expo Center, Sao Paulo,
Brazil,
www.abtcp2014.org.br
8: PPI Awards -
Tetra Pak
Tetra Pak has announced the completion of a Euro
65 million upgrade for its packaging material plant
in Ponta Grossa, Brazil. The project increases the
capacity of the plant by 70% to 13 billion packs and
brings the Brazilian total to 22 billion, meeting both
domestic and export demands in the region.
Australian Paper
Australian Paper, a Nippon Paper Industries subsidiary, has recently seen a machine at one of its mills
hit by fire. The blaze started and was extinguished
on July 1 at the firms Maryvale mill in the state of
Victoria, which can produce around 280,000 tonnes/
yr of uncoated fine paper and 370,000 tonnes/yr of
various packaging grades.
Cascades
Cascades has announced that it will cease its kraft
paper manufacturing activities in the East Angus, QC,
plant because of unfavorable market conditions. Close
to 175 employees will be affected by the closure,
which will come into effect by October 3. The decision
means Cascades is leaving the kraft paper sector.
August 2014
w h a t s n e w
WHATS NEW
iong city, Guangdong province, China. The firm and its parent company
Guangdong Shaoneng Group would fund the project, which would cost
RMB 178.9 million ($29 million).
The firm currently has a capacity of 65,000 tonnes/yr of bamboo pulp
and 35,000 tonne/yr of uncoated printing and writing paper at the
same site.
Zhuji Paper has been losing money over the past years amid the weak
pulp and paper market in China. To increase profitability, the firm plans
to diversify into the tissue sector, using its in-house bamboo pulp
capacity as furnish. A specific timeline for the project is unknown so far.
IP to start Euro 20 million upgrade investment in
green production process at its Saillat mill in France
International Paper announced earlier this year an investment
of approximately Euro 20 million ($27 million) into its Saillat
mill, located in the French Limousin region, to further reduce
the facilities water emissions and offer customers an even
more environmentally friendly product portfolio. The implementation of the project will commence in the summer of 2014 and
is expected to be completed in 2015.
At its core, the investment involves advanced technology to
extract an improved quality of fiber from wood by using a
smoother process. The new process leaves fibers more intact
resulting in even higher quality paper, and at the same time further reduces water emissions by another 30% from the already
very good levels the Saillat mill is achieving today.
The investment will allow International Paper to offer an even
greater choice of top notch products to customers. It follows
other investments into the companys service capabilities and
modernization of its paper machines at the Saillat facility in
recent years.
The project is supported by local and national French and
European agencies, notably the European Union (through the
Limousin Region) and the Loire- Brittany Water Agency.
The company is partnering with Voith Paper for equipment supply, and
Robins & Morton for engineering services. The press section replacement is scheduled for completion in July 2015, with an estimated
downtime of 24 days.
160
140
120
100
80
60
00
01
02
03
04
05
06
07
08
09
10
11
12
13
14
Euro
110
95
80
65
00
01
02
03
04
05
06
07
08
09
10
11
12
13
14
185
240
Euro
January2000
2003 = 100
January
= 100
170
225
155
140
210
125
110
180
95
80
165
65
195
150 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14
135
120
105
90
03
04
05
06
07
08
09
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11
12
13
14
2008 RISI,most
Inc.
theindustrys
w h a t s n e w
WHATS NEW
The mont h in pict u res
The Wirral Grammar School for Girls has
won the Confederation of Paper Industries
PaperWorks Design and Technology competition for corrugated cardboard packaging
with an ingenious concept for cupcakes.
The judges decided that WGSGs imaginative design of outer corrugated packaging
which opens to reveal a smaller box inside
hiding the item stood out as best in the
competition.
ENVIRONMENT
with 43% believing that it is just getting started, and
Quote
39% believing it is the new norm.
SCA survey shows Canadian conof the month
sumers seeking green products
and services
APRIL affirms full compliance
The aim was to draw [De Guwith its sustainable forest
Canadians are increasingly looking
chts] attention to the violation by the
management policies in
for green products and services, and
Russian Federation of its WTO commitments.
response to Greenpeace
many are even willing to pay more
The import tariff increase that has been applied
accusations
for them, but they may be selecon coated paper and paperboard aims to protect
Asia Pacific Resources Internative on which they choose based
the interests of a few manufacturers established in
tional Limited (APRIL) affirmed
on the strength of environmental
Russia is in breach of the WTO Accession Protocol
that it is in full compliance with
claims. The findings, that suggest an
signed by Russia ahead of its accession in
its
sustainable forest manageimportant shift to mainstream green
August 2012,
ment
policies and that attacks
purchasing practices, are a result of
CEPIs trade & competitiveness director Bernard
on
its
credibility
by Greenpeace
an inaugural survey on green purchasLombard, telling RISI abut his meeting with EU
are
off-base.
ing behaviours and attitudes in Canada
Trade Commissioner Karel De Gucht to discuss
Were sticking to all the policies
commissioned by SCA, the maker of the
measures that the EU can take to protect
we
announced in January this year. Our
Tork brand of away-from-home hygiene
the interests of the European paSustainable
Forest Management Policy
products. As an international leader in creatper industry on the Russian
(SFMP)
is
being
vigorously
implemented and
ing an ethical and sustainable marketplace, SCA
market.
overseen by an independent, multi-party Stakeworked with Leger in Canada to capture in-the-moment
holder Advisory Committee. We are working towards a oneconsumer insights that reflect market trends.
to-one
commitment for conservation, meaning one hectare of
However, most of those purchasers look for third-party certification
conservation for every hectare of plantation area, said Michael
(33%) or conduct their own research (24%) to verify claims. This fact
Zampa, APRIL Director of Corporate Communications.
combined with the knowledge that their prime purchase driver is the
We have been identifying and protecting areas of high consercare of the environment itself (48%) rather than other motivations
vation value (HCV) in our land concessions since 2005. Overall,
means organizations should showcase their environmental commitment
we only use about 50% of our concessions for plantation
beyond their direct business offer.
establishment, with most of the balance being conservation or
Whether they are early adopters or just picking up on the trend, Canafor community use, he said.
dians on the whole are strong believers in green products and services,
August 2014
THIRD ANNUAL
Register Now!
For program updates, sponsorship information or registration
details please visit the event website or contact us directly.
mill
profile
ON TIME, ON BUDGET,
CLOQUET CONVERTS TO
SPECIALISED CELLULOSE
By GRAEME RODDEN, Executive Editor
The Minnesota mill is Sappis first North American facility to produce dissolving pulp
10
growth and returns by growing Sappis position as the worlds largest producer of dissolving pulp (1.3 million tonnes/yr). From a
capital and economy-of-scale perspective,
Cloquets pulp mill was ideally suited for the
conversion to dissolving pulp. We are well
positioned in the business with our low-cost
August 2014
profile
production capabilities.
Prior to the conversion, Cloquet was an
integrated mill as the kraft pulp mill fed two
paper machines, PM 4 and PM 12, producing about 350,000 tonnes/yr of coated
wood-free grades, and provided significant
pulp production for external sales. (see
sidebar.) Pulp capacity has dropped from
500,000 tonnes/yr to 330,000 tonnes, a
reflection of the higher purity requirements
of dissolving pulp.
The pulp mill uses a 100% hardwood
furnish, a mix of aspen and maple. The
Cloquet mill is triple certified in accordance
with the leading sustainable forestry chain
of custody certification bodies: FSC, SFI and
PEFC and the mill is proud to be associated
with these organizations and their efforts
to drive sustainable business practices. The
mill draws wood from Wisconsin and Michigan as well as Minnesota.
F I R S T S U P E R B AT C H
In 1996, Cloquet installed the first Sunds
Defibrator (now Valmet) SuperBatch pulping system. A second phase was installed in
1999. The washing process is press based.
The SuperBatch system paved the way
for Cloquets conversion. The mill had a
lower cost because of its starting base with
SuperBatch. Therefore, Cloquet was already
one of the most modern pulp mills in North
America before its conversion.
Other factors working in its favor were a
world-class environmental performance, a
good workforce and excess utilities capacity
steam, electrical, water and effluent.
Sappi fast tracked this project and
mill
11
mill
profile
12
lulose Center of Excellence, as well as Lenzing Technik to help make the translation
between the two processes and deliver the
quality objectives.
Also, at the same time we were making
the conversion at Cloquet, we were also
converting our Ngodwana (South Africa)
mill: 210,000 tonnes/yr Specialised Cellulose. As a result, resources were involved in
each of the mills capital projects.
Nonetheless, training was extensive,
but given that most of the project was
modifications/additions to well-understood
processes, and given that the mill had an
operation that needed to keep running right
until the final conversion steps, traditional
classroom training was minimized.
We involved the operators in all
project HAZOP reviews, DCS development
work including simulator times and some
classroom training, Schultz adds. The best
preparation was the hands-on problem
solving that took place on a day-to-day basis
to ensure the project was executed successfully.
The mill has three power boilers, two
of which are fired with wood waste while
the other uses natural gas. It also has three
August 2014
profile
mill
Mother
Nature did
not comply
In Schultzs words, the project began with
a flood and ended with a blizzard. Days
after the official groundbreaking, the
region was hit with massive rainfall that
flooded the St. Louis River causing some
damage at the mill and forcing it to shut
down.
Then, the winter of 2012-2013 was one
of the worst on record for Minnesota with
temperatures frequently dropping to -30C
and snowfall up to mid-May. During the
final tie-ins in April 2013, the mill suffered
through the highest monthly snowfall on
record in April.
Despite the worst that Mother Nature
could throw at Cloquet, the project came
in on time and on budget.
Ed. Note: Even the day I visited in late April
2014, I had to drive two hours through a
snowstorm to reach Cloquet.
13
mill
profile
Some history
The Cloquet mill is more than 115
years old, being opened in 1898 as a
groundwood pulp and newsprint mill.
Going through various owners, the mill
ended up in Potlatchs hands in 1964. PM
12 was added in 1989 (the 12th paper
machine in the company). Installed in
1941, PM 4 was rebuilt in 1983 and 1994
by Potlatch.
In 2002, Sappi purchased the mill.
Rebuilds of PM 12 followed in 2004 and
2013, and a rebuild of PM4 occurred in
2012. The wood room was rebuilt in 2006
to help increase wood yield. A finishing
room modernization was done in 2011
when the company brought some of the
assets of its shuttered Muskegon, MI, mill
to Cloquet.
New demineralizer building
14
In February 2013 the Chinese Ministry of Commerce (MOFCOM) announced it would conduct an
anti-dumping investigation of dissolving pulp from
the U.S., Canada and Brazil imported into China
during 2012.In April, MOFCOM released its final duty
determination and imposed final antidumping duties
on dissolving pulp exported to China from the U.S.,
Canada, Brazil. Sappi does not anticipate that the
duties announced will impact its business or ability to
service its customers due to the nature of its current
sales plans.
It is also important to note that while all of the
major producers of dissolving pulp in Brazil, Canada
and the U.S. were initially named in the request for
an anti-dumping investigation, Sappi was not named
because the Cloquet pulp mill did not produce dissolving pulp during the period of investigation. PPI
August 2014
China Paper is the original show in China since 1987. The event features the newest
equipment, technologies and services related to all of Asias paper industries. The last China
Paper show in Shanghai proved once again the excellent reputation and track record of the
event with visitor figures up 11% from the year before. More than 7300 highly qualified
attendees and buyers from across China and 52 other countries could enjoy an exhibition of
almost 400 companies.
Find out more, visit www.chinapaperexpo.cn
Organisers:
the ppi
interview
By Davic Price
FFIF CEO sees light at the end of tunnel for the Finnish
forest products industry
The changing
forest products industry
During a recent Finnish Forest Industries Federation
(FFIF) breakfast event held in London, David Price, who has
many years experience covering the forest products industry, spoke with FFIF CEO Timo Jaatinen.
3. How has the FFIF managed the huge job losses in the
industry?
Our industry is undergoing a global transformation. The
growth in demand for printing and writing paper has slowed
down due to the expansion of digital media. Investments in
Finland dropped after the start of the European economic
crisis, and mill closures were unfortunately unavoidable.
On the other hand, companies have outsourced operations
Pulp & Paper International (PPI) A u g u s t 2 0 1 4
17
the ppi
interview
BIO-BASED IS
BETTER
A smarter solution for coated paper and board.
800-582-8728
www.PenfordProducts.com
Products Co.
maintenance
By TERRY WHALEN
BACK TO BASICS
19
maintenance
Work Order
Job
Description
Area
Asset
Planner
Misc
Date
B070049
Replace #1 Kamyr Floor Valve or Valves - (V64A, 64B, 65A or 65B) - Valve(s) TBD
Digester - 221
Vessel - 012010
G Lopez
Staging Required
Location
At low pressure feeder floor outside of control room on the southeast side.
Job Steps
Crew
Job
Hours
Man
Hours
PF
0.80
1.60
CA
4.00
8.00
PF
PF
PF
0.50
0.10
0.10
1.00
0.10
0.20
PF
3.00
6.00
PF
0.50
1.00
PF/YC
0.80
2.40
6.00
12.70
PF
PF
0.10
0.10
0.20
0.20
Remove the Handwheel(s) from the valve(s), rig and remove the 50" X 50" floor
plate and set aside away from work area. See attached image for details.
SAFETY: Use Yellow Caution Tape and barricade the area.
Rig Valves for removal - make sure to properly distribute the load.
With one pipefitter on the staging below the floor and other pipefitter above,
safely unbolt the valve flanges and lift valve. SAFETY: The pipefitter above the
valve must be in control of the 1 Ton Chain Fall and all must pay attention to load
shifting.
SAFETY: when working from staging use good body mechanics when
bending, reaching etc.,
When valve is lifted, place the valve on 4 wheel carry cart and transport to the
North side of #1 Kamyr low pressure feeder for yard crew to lower to ground
level.
Contact Yard Crew and notify them to mobilize the Mini-Grove (with Jib attached)
to lower old valve and to lift new valve. Place new valve on 4 wheel carry cart
and transport to work area.
Total Hours:
Fig. 1 - Kamyr job plan
20
August 2014
maintenance
#1 Kiln
1. Install new roller unit
a) Remove existing thrust roller unit.
b) Install new roller unit.
This task will consist of 4 men for 4 12 hour shifts.
192 Man Hours
NTE $20,000.00
2. Install new gear cover and labyrinth seals.
a) Remove existing gear cover.
b) Remove existing uphill and downhill seal plates.
c) Grind shell as required.
d) Layout and install seal plates.
e) Install gear cover.
f) Minor modifications to cover supports are
included, if necessary.
This task will consist of 3 men for 6 12 hour shifts.
216 Man Hours
NTE $25,000.00
3. Install new feed end seal, plates and riding band.
a) Gouge loose existing riding band.
b) Grind shell.
c) Install new riding band.
d) Install new seal plates.
This task will consist of 3 men for 3 12 hour shifts.
108 Man Hours
NTE $25,000.00
4. Install new oil wiper @ gear cover.
This task will consist of 2 men for 12 hours.
24 Man Hours
NTE $25,000.00
5. Remove end caps from all trunion rollers.
a) Check bearings.
b) Check thrust buttons.
c) Clean and check oiling system.
This task will consist of 4 men for 5 12 hour shifts.
240 Man Hours
NTE $25,000.00
21
maintenance
22
would require 200 man hours and that is what they are
going to invoice you for. However, if the purchasing
person has a detailed step plan developed by one of
your maintenance planners or engineers stating the
work should require only 120 man hours, a discussion
must ensue. The discussion is not about who is right or
wrong. Rather it promotes opportunities for learning,
enables mill personnel and contractors to focus on
results rather than activities, allows for a clearer understanding of the work to be performed by the contractor, and strengthens the mill-contractor partnership.
To illustrate what we mean by step plan, see Fig. 1.
Another real example for your consideration:
Major mechanical work was required on two lime
kilns during an eight-day annual outage at a South
Carolina mill. The contractor bid the job with a lump
sum proposal of $1 million and was awarded the
contract. Upon review of the bid with maintenance
and purchasing personnel, it was concluded that
the work would be more efficiently done on a time
and materials contract. The final cost of the work
was roughly half of the initial bid, a cost reduction of
approximately $500,000. The effort required to secure
this reduction was surprisingly little. It did however
require the mill to modify its approach to this long
time contractor and ask different questions than they
had asked in the past. The highlighted copy on page 2
illustrates a wide variance in the man hours required
to perform the five jobs listed, but only a small variance in the fees being charged. In fact, four of the jobs
have identical quotes.
In another situation at an Arkansas mill, a package of larger jobs was placed for bids, the winning bid
was a $906,000 lump sum proposal. The planner who
was to oversee the work felt uncomfortable with some
of the details of the proposal. In partnership primarily
with maintenance foremen and craftsmen, it was
determined that there was far too many man hours
in the proposal for the scope of work. A new time and
material contract was developed and the reduction in
this example was approximately $400,000.
The opportunities are not always hidden in the
$1,000,000 proposals; they appear in every size of
contractor proposal presented. With an outage approaching an Arkansas mill was planning some metal
work around one of the paper machine. It wanted to
replace three 25-ft steel beams, and because of the
corrosive environment the beams were to be placed
August 2014
maintenance
Start
3/17/14
Start 3/17/14
Monday
3/17/2014
7am 7pm
Tuesday
Wednesday Thursday
3/18/2014 3/19/2014 3/20/2014
7am 7pm 7am 7pm 7am 7pm
Friday
3/21/2014
7am 7pm
Saturday
3/22/2014
7am 7pm
Sunday
3/23/2014
7am 7pm
Monday
3/24/2014
7am 7pm
Tuesday
Wednesday Thursday
3/25/2014 3/26/2014 3/27/2014
7am 7pm 7am 7pm 7am 7pm
Friday
3/28/2014
7am 7pm
Cool Down
Cool Down
Pull Hood
Pull Hood
Out
/ Drive Work
Clean Out Clean
/ Drive
Work
DEMO
DEMO
Brick Work
Brick Work
Chain Work
Chain Work
Remove Deck / Pull Hood
Remove Deck / Pull Hood
Burner Management
Burner Management Checkout
Checkout
Light Off
Light Off
Direct Labor: $
Per Diem and Travel: $
Material: $
Total Cost: $
Total 12 hr Shifts: $
Labor Rates
47,281.00
12,834.00
96,323.00
156,438.00
-
Linear Ft
# of Sections
30
Total
BL total MH
Mech B
Total Hour/Craft
Step Plan
Hours
Super
WF
Mech
SD
TK
Watch
MH
GF
BL
Mech B
LBR
CW
HW/BW/FW
Material List
Quantity
Total Hrs
Unit
cost/unit
overage
# Pallets
ea
CW
Watch
Total
Total Duration
Average Manpower/Craft
LBR
Total Cost $
Total Sum
Total
Lbs
ea
ea
ea
Total
23
maintenance
24
August 2014
bleaching
By MARK WILLIAMSON
BURGO ARDENNES
STABILIZES BLEACHING PROCESS
Burgo Ardennes
bleach plant
25
bleaching
26
bleaching
ClO2
H2SO4
O3
Filtrate B0
H2O2
NaOH
H2SO4
O2
ClO2
ClO2
HD 4000
WP6
Oxytrac
WP8
HD
B0
Cormec5
D1
Filtrate
pH
C%
Kappa
EOP
pH
Kappa
C%
D2
Filtrate
pH
pH
Temp Cormec 5 C%
Kappa +
Brightness
Filtrate
pH
pH
Kappa+
Brightness
Cormec 5
C%
Brightness
Metso
The control guarantees were tested in the summer of 2013 and the results were better than the guarantees. Brightness variability was reduced by 47.9%
and chlorine dioxide consumption was reduced by
8.7%. The project was accepted.
O P T I M I Z AT I O N C O N T I N U E S
But this was not the end of the task to maintain and
improve the controls. The mill planned to increase
production from 1,015 tonnes/day to 1,100 tonnes/
day. This would affect the residence time in the
bleaching towers hence change the dynamics of
the bleaching chemical reaction. With a shorter
residence time the consumption of chemical went
up as expected. Metso retuned the controls for the
shorter residence time and different control dynamThe KappaQ Analyzer
takes online samples
of pulp from five
points in the process
27
coating
THRIVE THROUGH
Higher quality, high-speed printing presses, improved environmental performance are but some of the demands
suppliers such as Cargill must meet to help customers.
28
August 2014
coating
INNOVATION
From research to the market, Cargill knows a
company needs to understand customer demands
By ANDREAS BECKER
aper coating technology has seen a fast development during the last 50 years. Machines
got faster and wider, more efficient by utilizing
different application concepts also in combinations.
Coating color formulations were adapted to meet
the increasing demands of production with regard to
rheology, binding and quality of the coated papers.
Starches as well as starch preparation have seen
similar developments to enable higher coating solids
at high speeds with high amount of starch based
binders possible to get optimal cost performance,
runnability and quality.
Cargill set up its Application and Development
Center (A&DC) in Krefeld, Germany, in the mid1960s being a partner to the paper coating industry
enabling the development of starch based binders
alongside and in close cooperation to the most actual
technologies. In the early 1990s, Cargill was the first
to develop a product for filmpress high solids coating
with smooth rod premetering.
During the last couple of years the paper industry
in Europe has seen a variety of challenges and
changes. Starting with a higher degree of consolidation coupled with overcapacity in the graphic sector
as a result of new media and IT the industry nowadays is focusing on cost optimization at a maintained
quality.
To face the market challenges Cargill is trying to
help its customers thrive by proposing innovative
solutions and optimizing their recipes to meet their
needs. Its understanding of coating technology is
the basis for its success as a leading manufacturer of
coating starches.
The Application & Development Center is further
backed up by satellite operations in Vilvoorde (BelPulp & Paper International (PPI) A u g u s t 2 0 1 4
29
coating
30
Obtained from renewable resources which secures durable availability, the C*iBond wet-end starch
developed by Cargill achieves a better or at least
similar performance than any other raw materials.
This solution increases paper machine runnability and decreases the risk of paper web breaks. It
ensures quality performance over time and plays a
key role in the total retention and dewatering.
ACHIEVING HIGHER EFFICIENCY IN
W E T- E N D P R O C E S S
Having a higher starch paste viscosity which leads
to a high level of ash retention, Cargills solution proposes high bonding with pronounced dry strength
properties and offers paper makers additional cost
saving through fiber replacement.
For dewatering behavior C*iBond delivers
significant benefits. Its dewatering time at 1% addition is close to that of a cationic potato starch at
0.6% addition. This means higher machine speed
can be targeted, which in turn leads to further cost
optimization. In addition C*iBonds low impact on
furnish charge neutralization enables either high
addition levels if strength increase is desired, or allows fiber replacement with cheaper alternatives to
reduce costs.
Cargills patented solution has been designed to
match modified potato starch performance while
remaining a long-term and cost effective alternative. Compared with a potato starch with the same
cationic degree of substitution, Cargills C*iBond
customers identified a lower starch consumption,
better ash retention as well as first pass retention
combined with similar paper strength.
C*iBond wet-end starch is part of Cargills comprehensive package of services and tools to help its
paper making customers businesses thrive.
Andreas Becker is Global Technical Manager Paper,
Cargill PPI
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coatings
32
Heiko Diehl, the BASF manager responsible for the paper chemicals division, explains:
The most important requirement for the
barriers is that the breakthrough time which
is the period until a barrier can become
permeable and allow health hazardous substances to penetrate into the food is longer
that the shelf-life of the packaged product.
Our barrier coatings can be imagined as
being like a close meshwork that allows only
certain molecules to pass through, continues
Diehl.
According to BASF, only very small molecules like water vapor can pass. Larger molecules like mineral oil residues cannot cross. In
addition, the polar nature of the BASF barriers
hinders the migration of the molecules.
BASF said that developing the barrier
effect for large molecules was not the only
challenge when designing the various coating solutions. The coating has to be flexible
enough to stop fractures when the cardboard
is folded and has to be capable of being easily
removed in the recycling process.
The company works closely with one of
Europes leading manufacturers of folding
cartons and boxes, Van Genechten in Kempten in Germany. The company processes
about 200,000 tonnes/yr of cardboard. Michael Avemarg, innovation manager for materials says: We anticipate that strict limits will
be imposed and have already modified our
production lines. To develop optimal coating
solutions for our manufacturing process,
we are already cooperating with BASF and
testing products in our plants. For the jointly
developed WLC Food Safe coating based on
BASFs plastic Ultramid, the company won
the German Packaging Prize last year.
Sappi Fine Paper Europe is also addressing concerns about migration.
Developed in partnership with BASF and
Eurofins the company has launched Algro
Guard M and Leine Guard M barrier paper
grades. The grades were developed to allow
brand owners to use their current recycled fiber
based folding boxes, shelf ready packages and
transport boxes. The food inside is protected by
inner bags, pouches and sachets manufactured
from the Sappi mineral oil barrier papers.
The integrated solution of mineral oil
barrier functionality combined with excellent
heat sealing properties minimize converting
process steps and considerably reduce costs
in the supply chain, comments Ren Khler,
product group manager Flexpack Sappi Fine
Paper Europe.
Mayr-Melnhof Kartons product contribution to the mineral oil migration issue
is the result of a two-year comprehensive
test project with leading multinational food
producers. The end result is its cartonboard
product Foodboard, which has a distinctive functional barrier on the food contact
side of the board.
Careful consideration has also been given
to how the board performs once it is on the
converting line. The company states that two
million boxes produced so far is evidence of
August 2014
coatings
BASF has developed various barrier solutions to answer the problem of migration
33
recovery
NEW OPPORTUNITIES
FOR AUTOMATION
Efficient chemical recovery
processes are vital to the economic
success of pulp mills
By THANH TRUNG
34
August 2014
recovery
35
recovery
Fig. 4 - Comparison between traditional density control and TTA control using FT-NIR
36
August 2014
recovery
Fig. 5 - Contour plot relating primary air flow with black liquor solids content to green liquor reduction efficiency. Red indicates
higher RE
37
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classifieds
CLASSIFIEDS
CAN-AM MACHINERY, INC
W W W. C A N A M I N C. C O M
Interstate Paper
www.canaminc.com/lincoln
www.canaminc.com/interstate
www.canaminc.com/foxriver
www.canaminc.com/wetlap
94 Wire Width
Domtar: Plymouth, NC
New in 2008
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Mitsubishi Paperchine
Phone: 978-343-4400
Visit the RISI Market Place online for more information on products and services at www.risi.com/marketplace
ADVERTISERS INDEX
page #
website
AdForum...................................................................................... 16.........................www.chinapaperexpo.cn
CRI................................................................................................. 2.........................www.cricatalyst.com
Deublin...................................................................................... IBC.........................www.deublin.com
HP ColorLok.............................................................................OBC.........................www.colorlok.com
MIAC.............................................................................................. 4.........................www.miac.info
PAP-FOR Russia........................................................................... 15.........................www.papfor.com
Penford........................................................................................ 18.........................www.penfordproducts.com
RISI China Intl Recycled Fiber Conference.................................. 9.........................www.rcpconference.com
RISI Markets & Prices Service..................................................... 31.........................www.risi.com/europe
Thiele......................................................................................... IFC.........................www.thielekaolin.com
39
RISI viewpoint
RISI VIEWPOINT
Newsprint conversions to packaging gaining momentum
By Derek Mahlburg, Senior Economist, North American Graphic Paper, dmahlburg@risi.com
Newsprint demand in North America and Western Europe
has been in a state of perpetual, and steep, decline for the
past decade, forcing producers to find new markets for their
products or make major capacity adjustments. One way in
which the industry has approached this problem has been
through an increased focus on offshore exports, but now that
newsprint demand is sinking even in emerging markets like
Asia and Latin America, producers will find it increasingly
difficult to place excess newsprint tonnage offshore. This has
forced producers to once again search for a new market for
their output, and conversion to packaging grades has become
an increasingly popular tactic, particularly in North America.
By the end of 2014, the North American newsprint industry will have converted a total of 925,000 tonnes of newsprint
capacity to a variety of packaging grades, mostly recycled,
since 2011, with 468,000 tonnes of these conversions occurring
in 2014 alone. Newsprint producers have experimented with
packaging grades for some time, including AbitibiBowaters
(now Resolute Forest Products) abandoned 2010 attempt to
convert its Coosa Pines mill to packaging grades.
SP Fiber led the way
However, the trend did not truly take off until companies
gained experience with this conversion and packaging producers began to take an interest in moving out of the stagnant
newsprint market altogether. SP Fiber Technologies led the way
by converting a machine at its mill in Dublin, GA, in 2011, and
the company reduced its newsprint capacity by an additional
325,000 tonnes in 2013-2014. Atlantic Packaging converted the
idle newsprint machine at its Whitby, ON, mill in the second
quarter of 2013, and it will be joined by PCA/Boises conversion
of the remaining active newsprint machine at the DeRidder,
LA, mill later this year. Finally, Kruger is reportedly studying a
possible conversion of a 214,000-tonne/yr machine at its TroisRivires, QC, mill, demonstrating the North American newsprint industrys continued enthusiasm for alternative grades.
This trend has spread to Europe, although last years wave
of nearly 1.0 million tonnes of newsprint capacity reductions has made the immediate need for supply adjustments
somewhat less urgent. Nonetheless, the European industry
will inevitably face oversupply in the future, and producers
will make every attempt to keep their equipment operating.
Already, SCAs Ortviken, Sweden, mill is scheduled to complete
40
Time is money
TheEnhancedFSUStationarySiphonSystem
saves both
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