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Rethinking the paper cup — beginning with extrusion process optimization for compostability and recyclability, TAPPI Journal June 2021
ABSTRACT: More than 50 billion disposable paper cups used for cold and hot beverages are sold within the United States each year. Most of the cups are coated with a thin layer of plastic — low density polyethylene (LDPE) — to prevent leaking and staining. While the paper in these cups is both recyclable and compostable, the LDPE coat-ing is neither. In recycling a paper cup, the paper is separated from the plastic lining. The paper is sent to be recycled and the plastic lining is typically sent to landfill. In an industrial composting environment, the paper and lining can be composted together if the lining is made from compostable materials. Coating paper cups with a compostable performance material uniquely allows for used cups to be processed by either recycling or composting, thus creating multiple pathways for these products to flow through a circular economy.A segment of the paper converting industry frequently uses an extrusion grade of polylactic acid (PLA) for zero-waste venues and for municipalities with ordinances for local composting and food service items. The results among these early adopters reveal process inefficiencies that elevate manufacturing costs while increasing scrap and generally lowering output when using PLA for extrusion coating. NatureWorks and Sung An Machinery (SAM) North America researched the extrusion coating process utilizing the incumbent polymer (LDPE) and PLA. The trademarked Ingeo 1102 is a new, compostable, and bio-based PLA grade that is specifically designed for the extrusion coating process. The research team identified the optimum process parameters for new, dedicated PLA extrusion coating lines. The team also identified changes to existing LDPE extrusion lines that processors can make today to improve output.The key finding is that LDPE and PLA are significantly different polymers and that processing them on the same equipment without modification of systems and/or setpoints can be the root cause of inefficiencies. These polymers each have unique processing requirements with inverse responses. Fine tuning existing systems may improve over-all output for the biopolymer without capital investment, and this study showed an increase in line speed of 130% by making these adjustments. However, the researchers found that highest productivity can be achieved by specifying new systems for PLA. A line speed increase to more than 180% and a reduction in coat weight to 8.6 µm (10.6 g/m2 or 6.5 lb/3000 ft2) was achieved in this study. These results show that Ingeo 1102 could be used as a paper coating beyond cups.
Conference papers
How A Major Pulp & Paper Manufacturer Reduced MRO Inventory Using RCM Principles, 20PEERS Conference
How A Major Pulp & Paper Manufacturer Reduced MRO Inventory Using RCM Principles, 20PEERS Conference
Journal articles
Magazine articles
TAPPI News, Paper360º March/April 2020
TAPPI News, Paper360º March/April 2020
Achievements in Industrial Ozone Bleaching, 2011 International Pulp Bleaching Conference
Achievements in Industrial Ozone Bleaching, 2011 International Pulp Bleaching Conference
Na2CO3 as Alkali in Hydrogen Peroxide Bleaching of Softwood Kraft Pulp, 2011 International Pulp Bleaching Conference
Na2CO3 as Alkali in Hydrogen Peroxide Bleaching of Softwood Kraft Pulp, 2011 International Pulp Bleaching Conference
On the Role of Copper Ions in Alkaline Hydrogen Peroxide Bleaching of Kraft Pulps, 2011 International Pulp Bleaching Conference
On the Role of Copper Ions in Alkaline Hydrogen Peroxide Bleaching of Kraft Pulps, 2011 International Pulp Bleaching Conference
Modern Bleach Plant Advanced Process Control utilizing Inline Sensors and Model Predictive Control, 2011 International Pulp Bleaching Conference
Modern Bleach Plant Advanced Process Control utilizing Inline Sensors and Model Predictive Control, 2011 International Pulp Bleaching Conference
ASSESSMENT OF PULP MACHINE WHITEWATER QUALITY OF MARKET KRAFT PULP MILLS, 2011 International Pulp Bleaching Conference
Assessment of Pulp Machine Whitewater Quality of Market Kraft Pulp Mills, 2011 International Pulp Bleaching Conference
Combining Chlorine Dioxide and Molybdate Catalyzed Hydrogen Peroxide for Improved Delignification of Canadian Hardwood and Softwood Pulp, 2011 International Pulp Bleaching Conference
Combining Chlorine Dioxide and Molybdate Catalyzed Hydrogen Peroxide for Improved Delignification of Canadian Hardwood and Softwood Pulp, 2011 International Pulp Bleaching Conference
Near-Neutral Final Chlorine Dioxide Brightening: Theory and Practice, 2011 International Pulp Bleaching Conference
Near-Neutral Final Chlorine Dioxide Brightening: Theory and Practice, 2011 International Pulp Bleaching Conference