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Unlocking the Power of Advanced Data Analytics: Techniques and Practical Strategies for Successful Implementations Panel Discussion, TAPPICon25

Beyond KPIs: Harnessing the Power of Data Obscurity, TAPPICon25

Recycled Food and Beverage Cartons as a Replacement for Declining Traditional Feedstock in Molded Pulp Production, TAPPICon25

Corrugated medium strength assessments in different flute structures, TAPPI Journal April 2026

ABSTRACT: Recent advancements in our ability to evaluate papers and our understanding of the mechanics of box failure have brought a renewed focus on measuring the performance of corrugated medium and an associated evolution of paper measurement approaches. This study evaluates the load curves, Hardness (where the fluted structure’s loading shifts away from an elastic response), and Concora medium crush test (CMT) values for a range of corrugated mediums in different common flute geometries. The shape of the load curve is a function of the geometry of the fluting profile and the relative stiffness of the paper, with smaller flutes and heavier papers reaching both the Hardness value and the ultimate load at lower deformation. Nonetheless, while the specific dynamics during the loading process vary, Hardness and CMT values correlate linearly between flute structures, even when testing specimens after different equilibration periods post-fluting. These correlations confirm the applicability of the standard A-flute CMT test to a broad range of papers and potential combined board flute structures, supporting quality assurance processes for medium production and optimization in corrugated board manufacturing.

Optimization of energy efficiency and condensate production in evaporation plants for a modern softwood pulp mill, TAPPI Journal April 2026

ABSTRACT: To meet the need to further improve thermal efficiency and environmental performance of kraft pulp mills, new systems and techniques have been developed within the evaporation plant. This paper describes these novel approaches and how they were implemented in a project completed in 2018 for a new evaporator and condensate treatment system supplied by Valmet at the SCA Östrand market pulp mill in Sweden. This project was part of a stepwise upgrade of the complete mill to increase the production capacity of the mill from 430,000 to 900,000 air-dried metric tons/year (ADt/y). As part of this upgrade, the mill had the objectives to increase the energy efficiency of the pulp mill and to minimize the air emissions as much as possible, the effluent volume, and the water usage in the mill. The mill also wanted to have the disposal of the biosludge in the black liquor, and the production of tall oil from black liquor soap, liquid methanol, and turpentine. This required that the new evaporation and condensate treatment system be very closely integrated into the other process departments of the mill, including integration of the hot weak black liquor flash vapor from the digester directly into the evaporator train and the production of multiple streams of clean evaporation plant condensate at the correct temperature for the bleach plant. Heat and mass balance calculation values, which were found to do very well in predicting the effect on actual mill operation, are also presented in this paper.

A systems approach for process debottlenecking towards a sustainable pulp and paper industry, TAPPI Journal April 2026

ABSTRACT: Increasing the competitiveness of the pulp and paper industry requires an effective optimization of its existing assets in line with a long-term vision for process transformation, production upgrade, and product diversification. Currently, pulp production increase is one of the main sources of additional revenue for the kraft industry. Likewise, energy efficiency is often employed as a cost-effective approach to reduce operating costs, enhancing the possibilities to lower fossil fuel consumption and contributing to a low-carbon economy. On the other hand, reaching higher production targets and facilitating process transformation, such as biorefinery implementation, heavily depend on the status and performance of a mill’s current infrastructure; therefore, a system analysis is needed to assess the new production requirements, the bottlenecks, and the interactions across departments. In order to obtain practical improvement solutions, direct and indirect impacts on process performance and resource utilization should be considered. This work provides an overview of the key challenges that need to be addressed for production increase and energy efficiency improvement. The methodology starts by a scope analysis for debottlenecking and screening capacity limitations vs. mill targets, followed by their ranking (bottleneck ranking diagram). Benchmarking, gap analysis, and root-cause techniques are applied to diagnose system inefficiencies. This mill-wide debottlenecking assessment is then used to guide the selection of a long-term sustainable operation and design a portfolio of improvement projects by avoiding cross effects of the short-term projects on the long term. A case study of a kraft pulp mill is used to illustrate the proposed methodology.

Biphasic 1-butanol/water delignification of miscanthus for manufacturing papermaking pulp, TAPPI Journal August 2026

ABSTRACT: Miscanthus has emerged as a promising nonwoody fiber source for papermaking and fiber molding as the world has sought alternatives to wood-based products. A diverse range of chemistries have been explored at the laboratory scale to turn nonwoody biomass into fibers; however, few have been successful at pilot or commercial scales. An emerging organosolv delignification chemistry that has demonstrated previous technical success is butanol/water, having been shown to produce papers with similar properties to other, more conventional chemistries, but offering the benefit of a built-in sugar and lignin coproduct separation. While a range of fiber lengths were achieved (0.45•0.95 mm), addition of sodium hydroxide (NaOH) to the butanol/water delignification chemistry resulted in fiber lengths comparable to commercially available hardwood pulps (0.7•1.0 mm). Lignin concentration was reduced from 19.1 wt% in the raw miscanthus to under 3.5 wt% for most trials. The lowest lignin concentration (2.5 wt%) was achieved at 180°C for 180 min with 50:50 butanol:water and 2 wt% acetic acid. Yet, the high severity of this condition (and similar ones) resulted in a significant truncation of fiber length, which is detrimental for papermaking applications. The highest quality pulp for papermaking was generated at 180°C for 180 min with 50:50 butanol:water and 10 wt% NaOH. This pulp had one of the longest fiber lengths, the highest brightness, and the highest hemicellulose concentration. Thus, butanol/water delignification, especially with NaOH addition, resulted in the successful production of cellulose-rich pulps that have potential in commercial papermaking and fiber molding applications.

Examination of scoring parameters of corrugated fiberboard, TAPPI Journal August 2026

ABSTRACT: One of the less interrogated aspects of corrugated packaging are scoring and scoring profiles, the intentional localized crushing of flutes to accommodate package folding and closure. This study explores the effect of scoring parameters on box compression test strength (BCT) of two balanced corrugated boards. Scoring differences produced BCT that varied by 10% for one board and less for the other board. Parameters from 4-point bending of scored specimens showed some correlation with BCT, while eccentricity and torsion parameters had less correlation. Different scores produced BCT differences that were not strongly predicted by most standard tests in the current study, implying other tests may be needed to examine the actual boundary conditions on a box during compression. In a few cases, aggressive scoring produced cracked score lines, and those containers had lower BCT than containers with uncracked score lines.

Investigating the causes of severe economizer tube thinning in a spent sulfite liquor (SSL) boiler, TAPPI Journal August 2026

ABSTRACT: In this study, the causes of tube thinning in the economizer of an ammonia-based spent sulfite liquor (SSL) boiler in a Canadian pulp mill are investigated. The tube thinning was most severe in the upper tube rows of the lowest economizer sections where the tube surface temperature ranges between about 180°C and 210°C. The location, the temperature range, and the results of a tube failure analysis indicate that some form of corrosion- erosion is the main cause for the tube thinning. The process is likely initiated by the formation of potassium bisulfate in tube deposits. We hypothesize that some areas in the economizer, including gaps in tube shields, have allowed for temporary buildup of deposits that were not fully removed by sootblowing. Potassium bisulfate is highly hygroscopic, so it readily absorbs moisture, forming an acidic solution leading to corrosion. The corrosion products are removed by the erosive effects of high velocity gas movement, causing the tube thinning. The high-speed fluid flow may be a result of sootblower action and/or enhanced flue gas velocity due to channeling. The tube thinning eventually leads to perforation and leakage.

Editorial: TAPPI Journal research themes in 2025 highlighted sustainability and process efficiency, TAPPI Journal February 2026

Each year, the pages of TAPPI Journal offer more than a collection of technical papers -- they provide a sanpshot of where our industry is appling its intellectual energy in research. Looking back at the January through November 2025 issues, there was a distant focus on improving materials performance, strenghtening process efficiency, and integrating sustainability considerations into existing manucaturing processes. A majority of this focus was centered on packaging for a variety of applications.