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Multifunctional barrier coating systems created by multilayer curtain coating, TAPPI Journal November 2020
ABSTRACT: Functional coatings are applied to paper and paperboard substrates to provide resistance, or a barrier, against media such as oil and grease (OGR), water, water vapor as measured by moisture vapor transmission rate (MVTR), and oxygen, for applications such as food packaging, food service, and other non-food packaging. Typical functional barrier coatings can be created by applying a solid coating or extruded film, a solvent based-coating, or a water-based coating to the paper substrate using various means of coating applicators.This paper focuses on water-based barrier coatings (WBBC) for OGR, water, MVTR, and oxygen barriers. The main goal was to create coated systems that can achieve more than one barrier property using multilayer curtain coating (MLCC). Curtain coating has emerged as the premier low-impact application me thod for coated paper and paperboard. This paper provides examples using MLCC to create coating structures that provide multiple barrier properties in a single coating step. Barrier polymer systems studied include styrene butadiene, styrene acrylate, vinyl acrylic, and natural materials, as well as proprietary additives where required to give desired performance. The paper also shows how the specific coating layers can be optimized to produce the desired property profile, without concern for blocking, as the addition of a non-blocking top layer can be applied in the MLCC structure as well. Experiments on base sheet types also shows the importance of applying the multilayer structure on a pre-coated surface in order to improve coating thickness consistency and potentially allow for the reduction of more expensive layer components.
Journal articles
Magazine articles
The use of hollow sphere pigments as strength additives in paper and paperboard coatings—Part 1: The predictive nature of packing models on coating properties, TAPPI Journal November 2020
ABSTRACT: Hollow sphere pigments (HSPs) are widely used at low levels in coated paper to increase coating bulk and to provide gloss to the final sheet. However, HSPs also provide an ideal system through which one can examine the effect of pigment size and particle packing within a coating due to their unimodal and tunable particle sizes. The work presented in Part 1 and Part 2 of this study will discuss the use of blends of traditional inorganic pigments and HSPs in coating formulations across a variety of applications for improved coating strength. Part 1 of this study focuses on the theory of bimodal spherical packing and demonstrates the predictive nature of packing models on the properties of coating systems containing HSPs of two different sizes. This study also examines conditions where the model fails by examining the effect of particle size on coating strength in sytems like thermal paper basecoats where the non-HSP component has a broad particle size distribution, and how these surprising trends can be used to generate better-than-expected thermal printing performance in systems with low HSP/clay ratios. Part 2 of this study focuses on the incorporation of HSPs of different particle sizes into paperboard formulations to affect coating strength and opacity.
Journal articles
Magazine articles
Research on flame-retardant paper prepared by the method of in-pulp addition of ammonium polyphosphate, TAPPI Journal May 2023
ABSTRACT: At present, the production of flame-retardant paper usually uses the impregnation method of phosphorus-nitrogen flame retardants in paper. There are few reports on the application of an in-pulp addition method. In this paper, the solubility of ammonium polyphosphate (APP) and its effect on flame-retardant paper were investigated for use in an in-pulp addition method. It was found that APP particles were square, with an average particle size of 21.88 µm. The particle size decreased significantly after immersion in water at 25°C for 24 h. Furthermore, most of the APPs were dissolved after immersion in water at 90°C for 0.5 h, and the residuals agglomerated and their shape turned into an amorphous form. The APP possessed strong electronegativity and could partially ionize in water. The solubility of APP was 0.18 g/100 mL water at 25°C and increased quickly when the temperature was higher than 30°C. Therefore, APP should be added to the pulp at temperatures below 30°C. The tensile strength of the paper initially increased with the addition of APP, and it reached the maximum value when the APP content was 10% and then gradually decreased. The limiting oxygen index (LOI) value of the paper was 28.7% when the added amount of APP was 30% and cationic polyacrylamide (CPAM) was 0.08%, reaching the flame-retardant level.
Journal articles
Water and grease resistance of paperboard coated with long chain cellulose fatty acid esters using electrostatic powder coating, TAPPI Journal April 2026
ABSTRACT: Fiber-based materials used for foodservice, takeaway, and other packaging applications must typically provide water and grease resistance. Simultaneously, there is growing interest towards bio-based and renewable barrier coatings. In this study we applied thermoplastic long chain fatty acid cellulose esters onto paperboard using electrostatic powder coating to create barrier properties of interest. Electrostatic powder coating provides a water-free process to tackle moisture-induced quality issues and to provide an even coating layer. Cellulose octanoate and palmitate esters were produced in pilot scale. These were ground into fine particles using liquid nitrogen and applied onto paperboard sheets using an electrostatic powder gun. The loosely packed coatings were fixed and fused onto the paperboard by hot pressing. We characterized the coated sheets for coating thickness, contact angles with water, water absorption, grease resistance (KIT), and olive oil barrier. Two commercial polyethylene powders were used as references. Our results indicated that the long chain cellulose fatty acid ester coatings were thermoplastic and hydrophobic with contact angles above 100°. Water absorption was similar to the reference coatings. While grease resistance was lower than with the references, the cellulose ester coatings slowed down diffusion of olive oil through the paperboard. Cellulose octanoate ester with a lower melt viscosity already provided smooth coatings after the initial hot pressing step, while in most cases, the second post hot pressing step further improved the barrier properties.
Journal articles
Pilot-made, highly extensible paper for dry 3D forming, TAPPI Journal May 2025
Cellulose fiber-based packaging materials must perform well in demanding three dimensional (3D) forming process conditions. On the other hand, the development of manufacturing concepts is required for improved competitiveness of bio-based materials. This study covers some key factors that influence the extensibility of cellulose fiber-based structures and presents a pilot-scale development study of a 3D formable material concept. Bleached softwood kraft (BSK) pulp from a Nordic pulp mill was used in the pilot trials. Cellulose-based webs were formed using water-laid and foam-laid web forming using a pilot paper machine. For the water-laid forming, the BSK pulp was refined by applying a high consistency (HC) phase at over 40% consistency, followed by a low consistency (LC) refining at 4% consistency. The BSK pulp was refined for the foam-laid forming by only applying lowconsistency refining. In the foam-laid web forming, anionic sodium dodecyl sulfate (SDS), two foamable latexes, and polyvinyl alcohol (PVA) were used as foaming agents. The pilot rolls were dried at a separate steam cylinder dryer pilot and compacted in-plane in the machine direction (MD) at a separate pilot machine. Tensile properties of the treated paper webs were measured and evaluated with respect to achieved web shrinkage. The same dimensional contraction brought by shrinkage was almost strained out in tensile testing. The results indicated that the shrinkage that occurred by drying and in-plane compaction depended on the pulp furnish. The water-laid material achieved about 30% elongation, whereas the foam-laid material achieved significantly above 50% elongation. The 3D forming performance of the dry materials was tested using fixed and sliding blank methods. The dry paper sheets performed well enough in 3D forming for application to many consumer package applications according to their extensibility.
Journal articles
Magazine articles
Study on the effect of aluminum diethyl phosphinate in synergy with ammonium polyphosphate on the flame retardancy of cellulose paper, TAPPI Journal April 2025
ABSTRACT: This paper involved the synergistic incorporation of ammonium polyphosphate (APP) and diethyl aluminum phosphinate (AlPi) as flame-retardant fillers for producing flame-retardant paper. The research revealed that APPs were square particles with a smooth surface, and their solubility was 0.29 g/100 mL at 20°C, which increased to 4.12 g/100 mL at 60°C. The surfaces of AlPis were rough and irregular. The solubility of AlPi was 0.023 g/100 mL at 20°C, and the solubility remained stable when the temperature increased. The addition of AlPi had a minor influence on the pulp beating degree. The tensile strength of kraft/APP/AlPi decreased with the increase of the AlPi addition. For a paper with 20 wt% APP and 0 wt% AlPi, the limiting oxygen index (LOI) value was 27.2%, and it burned completely at the eighth second during vertical combustion. When the AlPi additive content increased to 20 wt%, its LOI value increased to 32.2%, and the vertical combustion self-extinguished as soon as the flame was removed. Scanning electron microscopy (SEM) showed that the char residue of the kraft/APP/AlPi had a more complete fiber network structure than that of kraft/APP. The Raman spectroscopy indicated that the area ratio of the D (amorphous phase; disordered graphite vibration) band to the G (crystal phase; graphite carbon vibration) band (ID/ IG) ratio of kraft/APP/AlPi was lower than that of kraft/APP, meaning that the graphitization degree of the char residue of kraft/APP/AlPi was higher than that of kraft/APP, which indicated the kraft/APP/AlPi had better flame retardancy.
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
Optimizing Water and water vapor barrier properties of water-based barrier coatings
Functional coatings are applied to paper and paperboard substrates to provide resistance, or a barrier, against media such as oil and grease (oil and grease resistance; OGR), water, water vapor (moisture vapor transmission rate; MVTR), and oxygen, for applications such as food packaging, food service, and other non-food packaging. Typical functional barrier coatings can be created by applying a solid coating or extruded film, a solvent-based coating, or a water-based coating to the paper substrate using various means of coating applicators. Today, there is increasing interest in developing recyclable and more sustainable approaches to producing these types of packages. This paper focuses on water-based barrier coatings (WBBC) for water resistance and MVTR for medium barrier performance. The main goal was to improve the performance of existing barrier polymers using additives such as waxes. Barrier coated systems were evaluated in single layer laboratory coating studies. This paper reviews examples of improving the performance of barrier polymers studied, including styrene butadiene and styrene acrylate, using wax additives. Regulatory challenges with paraffin waxes have resulted in the focus on bio-waxes. The results showed that small amounts of bio-wax can significantly improve barrier properties, especially for water resistance and MVTR. The choice of the best combination of binder and wax is essential. The influence of the bio-wax additive on blocking tendency, coldset glue strength, or heat seal strength is negligible.
Journal articles
The influence of precoating layers on the performance of water-based barrier coatings, TAPPI Journal January 2025
Cellulose nanofibrils (CNF) on paper have been demonstrated to be an effective barrier against oxygen and grease and have been shown to improve the barrier performance of dispersion-based barrier coatings. The potential to produce paper grades that have good oxygen, grease, and moisture barrier properties is clear, but a better understanding of the synergies between CNF, other coating layers, and water-based barrier coatings (WBBC) is needed to optimize these systems. Different coat weights of a commercial WBBC were applied to papers that have a range of different qualities and thicknesses of CNF precoating layers. The same WBBC was also applied to pigmented coated paper, with various types of pigments and latex levels. Samples were characterized in terms of grease resistance, water vapor transmission rate (WVTR), and oxygen transmission rate (OTR) before and after folding. The results were contrasted to cases where the WBBC was applied to the paper with no precoating layer. When the WBBC is applied on a CNF layer or the pigmented coating layer, the performance of the WBBC for the water vapor barrier improves a significant amount compared to when the WBBC is applied to the base paper with no precoating layer. This improvement likely comes from these precoating layers filling in the large paper pores, which leads to the WBBC forming a continuous layer at low coat weights. Folding decreases the moisture barrier performance to some degree, but the grease resistance is not influenced by folding when a CNF precoating layer is involved. Oxygen barrier properties are moderate for the CNF layer alone and are less than 5 cm3/m2/day when WBBC is coated on the CNF layer. This result likely comes from the barrier coating’s ability to repair defects in the CNF layer to stop the easy passage of oxygen in defect regions of the sample.
Journal articles
Magazine articles
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.