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Journal articles
Using multi-method analysis to identify challenging paper machine deposits and defects, TAPPI Journal March 2025
ABSTRACT: Based on its speed and versatility, Fourier transform infrared (FTIR) spectroscopy is the industry’s common starting point for analysis of a paper machine deposit or defect sample. However, certain contaminants and papermaking process additives cannot be precisely identified solely by infrared spectral interpretation. This lack of specificity could lead to a misinterpretation of the composition of the deposit or defect. A multi-method analysis uses data from two or more analytical techniques, including FTIR spectroscopy, microbiological staining/phase contrast microscopy, pyrolysis-gas chromatography/mass spectrometry (Pyro-GC/MS), and scanning electron microscopy-energy dispersive X-ray spectroscopy (SEM-EDX), to produce a more specific assessment of a sample’s composition. This paper discusses the use of a multi-method analysis in deposit and defect analysis and presents several case studies that demonstrate how this comprehensive approach can often produce an interpretation result of greater conviction and value to the papermaker.
Journal articles
Editorial: The emergence of AI in additives development, TAPPI Journal March 2025
ABSTRACT: The continuing evolution of artificial intelligence (AI) and its penetration into the core of the world of papermaking were undeniable at TAPPICon 2024 and especially within the content presented and sponsored by TAPPI’s Papermaking Additives Committee. On one side of the spectrum, there were traditional methods of chemical development and application grounded in natural intelligence, while on the other, there was the emerging presence of algorithmic decision-making and machine learning within the development cycle. The latter technology is brimming with the kind of promise that could reshape how additives are conceived, developed, and applied, turning what was once a matter of trial and error into something far more precise and previously out of reach.
Journal articles
Magazine articles
Optimizing OCC refining with defloccing, TAPPI Journal April 2025
ABSTRACT: Subjecting pulp to a high shear zone immediately after refining results in more efficient refining. This phenomenon was originally observed to benefit softwood pulp refining. It was attributed to floc reduction based on floc measurements in mill refiners and the observation of reduced headbox plugging. Hence, this phenomenon has been termed “defloccing.” The present work shows this technology also benefits refining of North American old corrugated containers (OCC). The combined results of several mill trials with OCC defloccing demonstrate the interactions between OCC refining intensity, defloccing technology, and other state-of-the-art refining improvements. At the same refining intensity, defloccing OCC on 100% recycled machines increases OCC refining efficiency by 15%, with greater efficiency improvement on machines that use softwood as well as OCC. Furthermore, it is shown that the benefits of defloccing are additive to refining improvements made in the refining zone of a refiner plate. Most OCC refiner plate designs can therefore benefit from the addition of a defloccing feature.
Journal articles
Improved barrier performance with microfibrillated cellulose, TAPPI Journal March 2025
ABSTRACT: In this work, the impact of microfibrillated cellulose (MFC) on the properties of water-based barrier coatings intended for food packaging have been explored. Commercially available MFC was used for improving the rheology and water retention of three different commercially available dispersion coatings (acrylic, styrene acrylic, and polylactic acid). Coatings were applied by rod to paper, and barrier properties were tested by measuring air permeability and water barrier properties. Results clearly showed that addition of MFC to water-based dispersion coatings improved the barrier performance of the final coatings.
Journal articles
Water-based adhesive penetration into paperboard and coated paperboard, TAPPI Journal January 2025
The setting of water-based adhesives in contact with paperboard is important in the production of boxes and other packaging, but the topic has received little attention in the literature. The penetration of the adhesive into the paper surface is important to get good bond strength through mechanical interlocking. The influence of the process conditions and the paper properties on this penetration is lacking. A water-based adhesive was applied to an uncoated and coated paperboard. The coating layer had two latex levels. Samples were characterized in terms of air permeability, void fraction, average pore size, and coat weight. The adhesive was applied to the samples in a mechanical press, squeezing a drop between two samples. The penetration of the adhesive was characterized with a silicone oil absorption method that measured the decrease in pore volume after the adhesive had been applied to approximate the pore volume taken up by the adhesive. The bond strength was measured with a peeling test. The penetration depth into uncoated paper did not depend on the application method parameters such as pressing time, pressure, or initial solids of the adhesive. The penetration depth ranged from 35•40 mm. The penetration into 10 pph latex content coated paper was similar to the uncoated samples, but reduced penetration was observed into the 40 pph latex content coatings. The results were compared to the limiting amount of adhesive that was obtained from the weight gain of the samples and to a simple model that is based on flow in porous media. Peel tests revealed that good penetration was needed, as well as a strong coating layer to obtain high peel forces.
Journal articles
Comparison of the application of polysaccharide-based barrier coatings on paper using film press and spray coating, TAPPI Journal January 2025
The growing demand for sustainable packaging has spurred research into biopolymer-based solutions and their application to paper substrates. This study compares the application of low solids, high viscous aqueous solutions of alginate and chitosan on two different paper substrates using a laboratory film press coater and a purpose-built spray coating unit, with a focus on barrier performance and practical industry considerations. Key parameters investigated are air flow rate, water vapor transmission rate, and grease resistance. Results showed that due to the low solids content of the applied biopolymer solutions, film press coating required a double-layer application for coat weights exceeding 4 g/m², making it less viable for industrial application. In contrast, spray coating allowed for higher application weights in a single step. The barrier properties of spray coated samples, compared to film press coatings, varied with the paper substrate: spray coating performed better on one substrate and worse on the other. Contact angle measurement of the substrates suggested that spray coating is more suitable for a more hydrophilic substrate because of improved surface wetting. The study also identified issues with drying conditions and pinholes affecting the quality of spray coated samples, indicating a need for further research to optimize these parameters.
Journal articles
Filtration performance of face masks and facepiece respirators used during COVID-19 pandemic, TAPPI Journal February 2025
ABSTRACT: The rapid spread of SARS-CoV-2 has created challenges for societies, healthcare settings, businesses, and institutions. To curb virus transmission, various measures like lockdown, social distancing, hand hygiene, and using appropriate personal protective equipment (PPEs), including face masks, have been recommended. Face masks and facepiece respirators are considered to act as barriers against microbial transmission from person to person. In this study, we selected barrier materials used during the COVID-19 pandemic that included four non-medical face masks and three facepiece respirators. Facepiece respirators were distributed by the U.S. Administration through pharmacy outlets. Results showed that facepiece respirator R95 has the highest filtration efficiency (above 99%), which remains more or less the same over different particle sizes. The N95 respirator’s filtration efficiency was lower than that of R95, but its barrier resistance was lower than that of the R95, indicating that it can be comfortably used over longer duration. Face masks were evaluated using ASTM F 3502-24 for their barrier performance. At 0.1 and 0.3 ìm particle size, domestically manufactured masks met the standard for higher performance. Interestingly, the results indicate that quality of raw materials and manufacturing standards play important roles, as is evident in domestically manufactured face mask and facepiece respirators.
Journal articles
Effects of different parameters on the morphology of electrospun cellulose acetate/polyaniline nanocomposite, TAPPI Journal February 2025
ABSTRACT: Cellulose is the most abundant naturally occurring polysaccharide. Its inherent mechanical stability, biocompatibility, biodegradability, and abundant hydroxyl groups available for derivatization provide benefits in the production of fiber-based materials such as conductive fibers. Cellulose derivatives, including cellulose esters such as cellulose acetate (CA), are readily generated in the fiber form following dissolution using a variety of solvents. Electrospinning is one of the emerging technologies with an outstanding ability to regenerate fibers in the nanoscale range. Polyaniline (PANI) is a conductive polymer that is popular for its high chemical stability, nontoxicity, good processability, and stable intrinsic redox state. This study explored the fabrication of a conductive PANI/CA nanocomposite through electrospinning. Working conditions, electrospinning variables, and solution parameters were established to produce coherent PANI/CA nanofibers. The effects of varying CA concentration, amount of PANI, molecular weight of CA, and feed flowrate on the morphology of the nanofibers were investigated.
Journal articles
Application of AI-based approach to control the papermaking process, TAPPI Journal March 2025
ABSTRACT: This paper explores AI’s role in revolutionizing the pulp and paper industry, and specifically in predicting wet tensile strength (WTS) for specialty-grade papers. Leveraging eLIXA technology, a 90-day study achieved a 15% reduction in chemical dosage and an 80% decrease in wet tensile standard deviation. The real-time dosage prediction led to optimizing the wet strength resin (WSR) consumption and improved process reliability. The self-learning models exhibited adaptability to changing variables, ensuring their robustness. Overall, this study highlights AI’s transformative impact on efficiency, cost savings, and product quality within the dynamic landscape of papermaking. The approach used for wet strength optimization has been used to optimize other aspects of pulp and paper production.
Journal articles
Editorial: Fundamental understanding enables new coating opportunities, TAPPI Journal January 2025
TAPPI's Coating, Printing, and Surface Enhancement (CPSE) Division pursues open exchange of technical information related to materials, equipment, and processes for the manufacture, quality control, and use of coated papers, paperboard, and other substrates. Much of this technical information is presented at sponsored conferences, including TAPPICon and the Advanced Coating Symposium. Based on feedback from these events, TAPPI Journal peer reviews the research from these events that adds significant value to the scientific community. In last year's November issue, we presented five peer-reviewed manuscripts based on presentations given at TAPPICon 2024.