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Determining operating variables that impact internal fiber bonding using Wedge statistical analysis
ABSTRACT: In this study, Wedge statistical analysis tools were used to collect, collate, clean up, plot, and analyze several years of operational data from a commercial paper machine. The z-direction tensile (ZDT) and Scott Bond tests were chosen as representative of fiber bond strength. After analyzing thousands of operational parameters, the ones with the most significant impact upon ZDT involved starch application method, starch penetration, and the amount of starch applied. Scott bond was found to be significantly impacted by formation and refining. Final calendering of the paper web has also shown an impact on internal fiber bonding.
Journal articles
Magazine articles
Control of malodorous gases emission from wet-end white water with hydrogen peroxide, TAPPI Journal October 2021
ABSTRACT: White water is highly recycled in the papermaking process so that its quality is easily deteriorated, thus producing lots of malodorous gases that are extremely harmful to human health and the environment. In this paper, the effect of hydrogen peroxide (H2O2) on the control of malodorous gases released from white water was investigated. The results showed that the released amount of total volatile organic compounds (TVOC) decreased gradually with the increase of H2O2 dosage. Specifically, the TVOC emission reached the minimum as the H2O2 dosage was 1.5 mmol/L, and meanwhile, the hydrogen sulfide (H2S) and ammonia (NH3) were almost completely removed. It was also found that pH had little effect on the release of TVOC as H2O2 was added, but it evidently affect-ed the release of H2S and NH3. When the pH value of the white water was changed to 4.0 or 9.0, the emission of TVOC decreased slightly, while both H2S and NH3 were completely removed in both cases. The ferrous ions (Fe2+) and the copper ions (Cu2+) were found to promote the generation of hydroxyl radicals (HO•) out of H2O2, enhancing its inhibition on the release of malodorous gases from white water. The Fe2+/H2O2 system and Cu2+/H2O2 system exhibited similar efficiency in inhibiting the TVOC releasing, whereas the Cu2+/H2O2 system showed better perfor-mance in removing H2S and NH3.
Journal articles
Magazine articles
Editorial: Agility and adaptation in a dynamic business world, TAPPI Journal January 2021
ABSTRACT: As we move into 2020, it's interesting to look back at the research topics that were covered in TAPPI Journal (TJ) the previous year. Members of the TJ editorial board organized diverse special issues on lignin, coating ,forming, and diverse papermaking and biorefinery topics, which are discussed in the following sections.
Journal articles
Magazine articles
Multiple recycling of paperboard: Paperboard characteristics and maximum number of recycling cycles— Part I: Multiple recycling of corrugated base paper, TAPPI Journal November 2019
ABSTRACT: Paper for recycling is an important fiber source for the production of corrugated base paper. The change in production capacity toward more and more packaging papers affects the composition of paper for recy-cling and influences the paper quality. This research project investigated the influence of the multiple recycling of five different corrugated base papers (kraftliner, neutral sulfite semichemical [NSSC] fluting, corrugating medium, testliner 2, and testliner 3) on suspen-sion and strength properties under laboratory conditions. The corrugated board base papers were repulped in a low consistency pulper and processed into Rapid-Köthen laboratory sheets. The sheets were then recycled up to 15 times in the same process. In each cycle, the suspension and the paper properties were recorded. In particular, the focus was on corrugated board-specific parameters, such as short-span compression test, ring crush test, corrugat-ing medium test, and burst. The study results indicate how multiple recycling under laboratory conditions affects fiber and paper properties.
Journal articles
Magazine articles
Lignin-based resins for kraft paper applications, TAPPI Journal November 2019
ABSTRACT: We investigated miscanthus (MS) and willow (W) lignin-furfural based resins as potential reinforce-ment agents on softwood and hardwood kraft paper. These resins might be sustainable alternatives to the commercial phenolformaldehyde (PF) resins. Phenol is a petrochemical product and formaldehyde has been classified as a carcinogen by the U.S. Environmental Protection Agency. The lignin used in this study was derived from hot water extraction (160ºC, 2 h) of MS and W biomass, and may be considered sulfur-free. These biorefinery lignins were characterized for their chemical composition and inherent properties via wet chemistry and instrumental techniques. The resin blends (MS-resin and W-resin) were characterized for their molecular weight, thermal behavior, and mechanical properties. Mechanical properties were measured by the resin’s ability to reinforce softwood and hard-wood kraft papers. The effect of adding hexamethylenetetramine (HMTA), a curing agent, to the resin was also examined. Mixtures of PF and lignin-based resins were investigated to further explore ways to reduce use of non-renewables, phenol, and carcinogenic formaldehyde. The results show that lignin-based resins have the potential to replace PF resins in kraft paper applications. For softwood paper, the highest strength was achieved using W-resin, without HMTA (2.5 times greater than PF with HMTA). For hardwood paper, MS-resin with HMTA gave the highest strength (2.3 times higher than PF with HMTA). The lignin-based resins, without HMTA, also yielded mechanical properties comparable to PF with HMTA.
Journal articles
Magazine articles
Creating adaptive predictions for packaging-critical quality parameters using advanced analytics and machine learning, TAPPI Journal November 2019
ABSTRACT: Packaging manufacturers are challenged to achieve consistent strength targets and maximize pro-duction while reducing costs through smarter fiber utilization, chemical optimization, energy reduction, and more. With innovative instrumentation readily accessible, mills are collecting vast amounts of data that provide them with ever increasing visibility into their processes. Turning this visibility into actionable insight is key to successfully exceeding customer expectations and reducing costs. Predictive analytics supported by machine learning can provide real-time quality measures that remain robust and accurate in the face of changing machine conditions. These adaptive quality “soft sensors” allow for more informed, on-the-fly process changes; fast change detection; and process control optimization without requiring periodic model tuning.The use of predictive modeling in the paper industry has increased in recent years; however, little attention has been given to packaging finished quality. The use of machine learning to maintain prediction relevancy under ever-changing machine conditions is novel. In this paper, we demonstrate the process of establishing real-time, adaptive quality predictions in an industry focused on reel-to-reel quality control, and we discuss the value created through the availability and use of real-time critical quality.
Journal articles
A targeted approach to produce energy-efficient packaging materials from high-yield pulp, TAPPI Journal August 2025
ABSTRACT: Unlike fossil-based plastics, wood-based packaging materials can be produced in an ecofriendly manner using wood chip residuals from sawmills and pulpwood. To produce high-yield pulp like chemithermomechanical pulps (CTMPs) for paperboard and liquid packaging, it is crucial to reduce the electric energy consumption during fiber separation. The ultimate objective is to revolutionize paperboard production by achieving a middle-layer CTMP process that consumes less than 200 kilowatt-hours per metric ton (kWh/t), significantly improving from the current 500•600 kWh/t energy demand. Optimizing the CTMP impregnation process of sodium sulfite (Na2SO3) in wood chips is crucial for achieving uniform softening, ideally at the fiber level. The properties of the fibers are significantly affected by the content of lignin sulfonates within the walls of the fiber and the middle lamellae. In this study, we employed in-house developed X-ray fluorescence (XRF) techniques, validated by beamline measurements, to map the distribution of sulfonated lignin within fibers. It also seemed possible to enhance the surface area of lignin-rich pulp fibers while losing minimal bulk by refining them with well-optimized low consistency (LC) refining. We aimed to achieve a highly efficient separation of coniferous wood fibers by co-optimizing the sulfonation and the temperature in the preheater and chip refiner. Additionally, we explored how lignin’s softening behavior and potential crosslinking influence subsequent unit operations, including pressing, peroxide bleaching, and drying, following the defibration process. In defibration during chip refining, the maximum softening of wood fibers is preferred to maximize fiber preservation and minimize energy consumption. However, optimizing the stiffness of finished pulp fibers is preferable to reduce bulk loss during paperboard production. It can strive to optimize processes to develop stronger, lighter, and more sustainable composite packaging materials. Reducing environmental impact and electric energy can help create a more sustainable future.
Journal articles
On the design of corrugated boards: A new FEM modeling and experimental validation, TAPPI Journal August 2025
ABSTRACT: This study presents a simplified finite element modeling (FEM) approach suitable for large structures made of corrugated boards, such as customized packages, based on a homogenization method, which is combined with correction factors for internal mechanisms. The homogenization process reduces computational time by transforming flute geometries into equivalent elastic models. In large deformations and in the presence of contact for a given geometry, the effective elastic modulus in the thickness direction, as well as the effective thickness of the structure, are corrected by two statistical Weibull distributions representing the contact and buckling mechanisms in a corrugated board. The Weibull parameters are obtained via experimental analysis, and such a process is then validated. The results demonstrate that the statistical parameters (â1 = 0.14, â2 = 1.31) can be used for the simplistic representation of corrugated boards, being computationally efficient. This research contributes to the optimization of corrugated packaging design, specifically by simplifying FEM models for faster, yet equally accurate, simulations.
Journal articles
Reinforcing folding boxboard ply stock with refined pulp and its effect on dewatering potential, TAPPI Journal February 2025
ABSTRACT: The folding boxboard (FBB) filler ply typically contains a significant amount of mechanical pulp such as bleached thermomechanical pulp (BTMP), bleached chemi-thermomechanical pulp (BCTMP), and chemi-thermomechanical pulp (CTMP), etc. It is usually reinforced with either refined broke from the same paper machine line and converting process or by utilizing traditional bleached kraft pulp (BKP). In response to the drive for improved/increased ply bond (to avoid undesired delamination), increased bulk, reduced basis weight, and minimized energy consumption, papermakers have experimented with various options and strategies. In between the common approaches, choices have been made between reducing the refining of the mechanical pulp, increasing the broke refining (more frequently practiced on the production scale), or increasing the BKP refining (a potentially superior choice). This study focused on a simplified approach to assess the impact of three reinforcement pulps with different refining levels on the dewatering of the filler ply. The reinforcement pulp was added to the core stock for the FBB filler ply — a mechanical pulp, BCTMP, with a drainability of 25 °SR. The proportions of the reinforcement pulp, hardwood bleached kraft pulp (HWBKP), were 20% of 30-35 °SR, 10% of HWBKP 50-55 °SR, and 5% of HWBKP 70-75 °SR. The intention behind using varying percentages of reinforcement pulp was to attain a controlled internal bond while enhancing bulk through increased mechanical pulp content. The dewatering potential of the stock mixtures was assessed at three vacuum levels — 4, 10, and 25 kPa — that can be found in progressive stages within production- scale forming sections. Our goal was to find an optimal reinforcement strategy for filler ply that would minimize the use of the reinforcement pulp, give better strength, retain bulk, and lower basis weight. The success of this strategy was verified with an actual FBB machine.
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.