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Journal articles
Modern NCG practice, TAPPI Journal July 2026
ABSTRACT: New innovations have been put in operation for collection and handling systems of noncondensable gases (NCGs) in modern kraft pulp mills. This work investigates technologies in new pulp mills that aim to achieve the benefits of odor-free processes while enhancing chemical circulation within the mill. It describes and discusses both past and current systems for collecting and handling NCGs. The mills studied have designed and implemented their NCG systems within the past 10 to 15 years. New innovations have emerged, offering promising methods to further reduce occasional sulfurous odor emissions from the kraft process. These methods explore pretreatment and sulfuric gas stream reuse options in process units where these gases are generated or during the transportation of these side streams to their final destruction site. Using modern practices outlined in this paper, malodorous gases can be collected to the extent that a kraft pulp mill is essentially odor-free pending operator errors or major equipment malfunctions. One of the difficult aspects is that NCG systems in kraft mills are often designed case-by-case, as well as by various equipment vendors and with varying numbers of destruction sites. The actual detailed design depends on the chosen layout, process configuration depending on individual equipment purchased, and even on the design practices of individual suppliers.
Journal articles
Permeability simulation for filled paper based on three-dimensional structural model developed by X-ray computed tomography scanning, TAPPI Journal March 2026
ABSTRACT: In this study, an in-depth exploration of filled paper was conducted to understand its structural and permeability characteristics. Cotton linter pulp and precipitated calcium carbonate (PCC) filler were utilized to prepare pure fiber paper, and PCC1 and PCC2 filled papers with different filler particle sizes. Then, the pore structure parameters of paper samples were characterized by mercury intrusion porosimetry, and the X-ray computed tomography (X-CT) scanning was carried out. Subsequently, the 3D microstructures were established based on the X-CT slice images, and the filler characteristic parameters and filler 3D distribution were quantitatively analyzed. Finally, permeation simulations in the thickness and horizontal directions were performed. The findings indicate that filling changes the paper porosity, and the pore tortuosity varies with direction. The estimated pore•throat radius distribution shows specific patterns for different papers. The fillers have different distribution characteristics in the paper samples. Moreover, the paper permeability differs with direction, with smallsized filler having a significant impact on fluid penetration in the thickness direction. Overall, this study provides an effective method for investigating internal paper filler and its distribution, which contributes to the understanding of paper structure•performance relationships.
Journal articles
Effects of in-plane straining on the out-of-plane delamination properties of paperboard, TAPPI Journal March 2026
ABSTRACT: Delamination strength is an essential property for the creasing and folding operations of paperboard into boxes. Due to fixation during creasing, the paperboard suffers in-plane straining. In the present study, we aim to increase our understanding of how in-plane straining affects the delamination properties of paperboard. Samples of paperboard were first strained in in-plane tensile loading, both in the machine-direction and in the cross-direction. Afterward, the paperboard is loaded in the out-of-plane (ZD) direction. Three different grades of commercial paperboard from two major manufacturers were tested in a climate-controlled lab. The results showed similar results for all grades of paperboard, with the delamination strength and the out-of-plane stiffness decreasing virtually linearly with pre-straining. With about 5% plastic in-plane straining, the strength was reduced by about 20% and the stiffness decreased by more than 50% for all grades of paperboard. Normalizing the strength and the stiffness with their values without pre-straining reveals virtually the same relation for all grades of paperboard. If proven to be a general result, this will prove valuable in reducing the demand for experiments.
Journal articles
Influence of base sheet properties on barrier coating performance, TAPPI Journal November 2025
ABSTRACT: Paper packaging offers a sustainable alternative to standard plastic-based materials, particularly for food and beverage applications. With reduced fiber treatment options like fluorochemicals, uncoated base stock often provides little-to-no effective barrier against liquid water, oil/grease, or moisture transmission. Despite the lack of natural barrier performance, base sheet properties can significantly influence the efficiency of applied waterbased barrier coatings. In this study, various base stock properties, such as caliper, porosity, roughness, and ash content, are reported to influence the barrier performance of styrene-acrylic and a copolymer of styrene-butadiene/styrene-acrylate based barrier coatings. These findings will help paper and board producers design better, more cost-effective, purposebuilt substrates for barrier applications in the packaging industry.
Journal articles
A laboratory-scale automated vacuum-assisted device for coating of cellulose nanofibrils onto paper, TAPPI Journal November 2025
ABSTRACT: An automated vacuum-assisted coating system was developed to deposit cellulose nanofibril (CNF) layers onto paper substrates, simulating potential industrial geometries while allowing precise control of web speed (10•20 m/min), vacuum time (up to 30 s), and applicator gap (0.5•0.9 mm). Vacuum assistance makes it possible to obtain coat weights over 5 g/m2 in a single pass and increases solids after coating from less than 10% to over 28%• 30%, reducing drying demand by more than 60%. Coat weights were tuned from 6 to over 11 g/m² by varying suspension solids (0.4•0.6 wt%), line speed, and filtration length (20•40 mm), with strong agreement between experimental data and model predictions. Barrier testing showed Kit test values for double folded samples of 9•12 and Gurley air resistances above 4 × 104 s once coat weights exceeded 7 g/m². Comparable performance was achieved with lower fines content CNF (60%) by increasing coat weight, providing technical flexibility and cost advantages for industrial scale-up.
Journal articles
The industry is entering a pivotal moment in which many of us find ourselves engaged in deep soul searching. Since the days of Francis Bacon when the illustrious triumvirate of gunpowder, the compass, and paper were the drivers of civilizations, our commu
The industry is entering a pivotal moment in which many of us find ourselves engaged in deep soul searching. Since the days of Francis Bacon when the illustrious triumvirate of gunpowder, the compass, and paper were the drivers of civilizations, our community has enjoyed a noble place at the table. Indeed, especially over the last 100 years, pulp and paper has quietly powered communication, commerce, and, more than ever today, packaging, thus representing a steady backbone for the continued stability of many global industries.
Journal articles
Magazine articles
Editorial: New coating grades require new tests: Barrier performance inside the package, TAPPI Journal November 2024
The TAPPI Journal special Coating issue is an annual issue that focuses on paper coating and coated papers. It is drawn from presentations at TAPPICon and from other submissions on the topic of paper coating. The TAPPICon 2024 Coating track was rich in high-quality technical content. In fact, the papers were of such significance that Coating members of the TAPPI Journal Editorial Board, which include me, Gregg Reed, and Gregory Welsch, decided that a second paper coating-related special issue would be appropriate for the TAPPI Journal editorial calendar. In addition to the current issue on Barrier Coating Testing, there will be another issue on Coating Fundamentals in early 2025.
Journal articles
Magazine articles
Test method and coating composition impact on measured moisture vapor transmission rate for waterborne coatings on paper, TAPPI Journal November 2024
ABSTRACT: Moisture vapor barrier is one of the necessary performance attributes for paper packages. Two methods are typically employed to assess the moisture vapor transmission rate (MVTR): the gravimetric cup method (ASTM E96) and the MOCON method (ASTM F1249). While those tests have been compared for free standing polymeric films, less is understood about their application in coated paper. Our results show that, despite a general agreement between the two methods, discrepancies exist where test protocols and material properties of coated paper impact the MVTR measurement. The measurement discrepancies can be explained by differences in local moisture concentration. Our study provides new insights on moisture vapor barrier assessment of waterborne coatings on paper and implications for achieving paper packages with improved barrier performance.
Journal articles
Magazine articles
Evaluation of folding effects on coating damage, TAPPI Journal November 2024
ABSTRACT: Barrier coatings on paperboard need to maintain integrity during converting and end-use for effective barrier performance. Folding is one of the most common deformations during converting; however, factors that affect damage during folding are not well defined. This is partly because methods to fold specimens and characterize damage are not standardized and the results are generally not transferable. In this work, we describe a method to fold paper specimens precisely and reproducibly. The keys to folding include using a defined geometry and controlled deformation. Multiple methods can be used to quantify damage; in this case, we use differences in permeability as a measure of how the coating becomes more open. Damage is sensitive to the degree of compression after the initial folding. Using a shim for support provides a defined amount of compression and minimizes the sensitivity to the applied pressure.
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.