Advanced Coating Materials and Operations Course

Advanced Coating Materials and Operations Course

TAPPICon in Atlanta, GA
Saturday, October 02, 2021 to Sunday, October 03, 2021

October 2-3, 2021 at TAPPICon!

Course Objectives

This course is designed to provide a holistic understanding of coating materials, processes, and applications while discussing recent advances and trends in functional packaging, barrier materials, and curtain coating from the leading professionals in the field.

Topics Covered

  • Pigments
  • Binders
  • Additives
  • Formulations Development and Characterization
  • Coating Equipment and Process Overview
  • Rheology
  • Coated Products Overview and Applications
  • Packaging Development
  • Barrier Materials
  • Curtain Coating 

Who Will Benefit?

This course will be beneficial to Process and Production Engineers, Product Development and Research Scientists, Technical Managers, Machine Supervisors, Suppliers or other technical people who are new to the field of coatings. This course will also be helpful for marketing, business planning personnel, and others who are involved in developing alternative grades.

Participants will gain a very good understanding of coating raw materials, how those are processed and prepared for the coating applications, rheology, application methods, and finishing with an overview of end-use applications for coated paper and paperboard. They will also get an excellent background on the new developments in packaging, barrier materials, and curtain coating from the leading professionals.

Course Prerequisites
There are no education prerequisites, but general familiarity with coating materials and processes is recommended.

Learning Outcomes
After successfully completing this course, participants will be able to:

  1. Have a good understanding of all key coating materials and coating formulations.
  2. Design new formulations based on the knowledge gained in this course.
  3. Understand how to process the coating formulations for various application technologies.
  4. Have a good knowledge of rheological aspects to better address the runnability challenges.
  5. Understand coating application methods and which methods best serve which end uses.
  6. Understand required coated paper testing with special emphasis on barrier properties and defects.
  7. Gain an understanding of market place in packaging, barrier materials, and curtain coating.
  8. Interact with leading experts in paper and paperboard coatings with your specific questions.
  9. Participate in case studies and examples of real-world situations and how they were resolved.

CEU Credits
Earn 14 Professional Development Hours or 1.4 CEUs after completion of this course.

Course Location and Timing
This course is held at the same location as TAPPICon 2021 on April 24 - 25, 2021 from 8:00 am-5:15 pm, opening an opportunity to save on travel and attend both events where you can network among peers and many other industry experts.

Course Co-Chairs
Lokendra Pal, North Carolina State University


Martti Tuomisto, Advanced Dynamics Corp.


For questions please contact at [email protected].


2021 Training Guide

Review the new 2021 Training Guide to learn more about the broad range of technical training resources from the TAPPI Academy.

Need Custom Training on this Topic?

The content for this course can be tailored specifically to your company's needs and delivered by a TAPPI instructor onsite at your location or as virtual and blended learning formats.
With TAPPI Company Classroom, we’ll work with you to determine your training needs and develop a curriculum to match your objectives.
Contact us to get started.

DAY 1  - 

8:00 – 8:15 AM Welcome and Introduction Lokendra Pal, NC State University, Martti Tuomisto, Advanced Dynamics Corporation Ltd.

8:15 – 10:00 AM Advances in Paper and Paperboard Coatings Chuck Klass, Klass & Associates

10:00 ­ 10:15 AM          Break

10:15 AM – 12:00 PM Pigments

Carbonates & specialty pigments (Talc, Gypsum, ATH, Alumina) Tim Bradley, Omya

Calcined Clay, TiO2, Plastics Pigments, Silica Prakash Malla, Thiele

12:00 – 1:00 PM            Lunch/Networking

1:00 PM – 2:00 PM Pigments

Kaolin &, Engineered Clays, Barrier Application Tony Lyons, Gregg Reed IMERYS

2:00 – 3:00 PM Synthetic Binders

Polymer Emulsions/PVOH’s Welsch, Gregory, Trinseo

3:00 – 3:15 PM               Break

3:15 – 4:15 PM Natural Binders

Starch and its derivatives, Engineered Starches Meggan Hostetler-Schrock, Tate and Lyle

4:15 – 6:00 PM Additives Gordon Bugg, Kemira


DAY 2 -

7:30 – 8:00 AM Review of the previous day/ Q&A Chuck Klass

8:00 – 9:30 AM Coating Processing

Makedown Process (45 min.) Gordon Bugg, Kemira

Rheological Testing (45 min.) – John Roper (??)

9:30– 9:45 AM                Break

9:45 – 11:15 AM Coating Applications/New Development  

Coating Application and Finishing (45 min.) – Pam Hynnek, Valmet

Curtain Coater Operation (45 min.) – Harald Döll of TSE Troller

11:15 – 12:15 PM Advanced/New Barrier Materials

Nanocellulose Barrier Materials (30 min.) – Lokendra Pal, NC State University

Additional Materials Discussion (30 min.)- Manoj Dixit

12:15 ­1:15 PM              Lunch Break/Networking

1:15 – 3:15 PM Coated Products Applications and Testing 

Overview of What Happens after Coating (30 min.)– Chuck Klass, Klass Associates

Barrier Performance/Defects Evaluation (45 min.) – Brian Einsla, Dow Chemicals

Recyclability, Composting, and Biodegradation Testing (45 min.)

3:15­ 3:30 PM                 Closing & Final Remarks

4:00-6:00PM                  Hagemeyer Happy hour

2021 Training Guide

Review the new 2021 Training Guide to learn more about the broad range of technical training resources from the TAPPI Academy.

Advanced Coating Materials and Operations Course

Dr. Lokendra Pal, NCSU
Dr. Lokendra Pal is an Associate Professor of Sustainable Materials and Engineering in the Department of Forest Biomaterials at NC State University. He has more than 19 years of global experience in the research and technological advancement of paper, coating and digital printing, and strong collaborations with industry worldwide.

Before joining NC State, he spent nine years working with Hewlett-Packard Company leading new product research and development programs. He has filed 39 patent applications and been granted 23 patents.

He obtained his Ph.D. in Paper and Imaging Science and Engineering from Western Michigan University. He teaches two senior-level courses on advanced process tools for manufacturing and a hands-on course on paper process analysis utilizing the paper pilot plant. He also teaches industrial courses on papermaking, coating and printing. He is the co-founder of Tissue Pack Innovation Lab (TPIL).

Pal research group is focused on the development of sustainable and functional bioproducts through green chemistry and advanced engineering of biomaterials to deliver top-class hygiene, functional and smart packaging, and flexible electronics/3D printable materials and products that benefit society, as well as the environment.

Chuck Klass, Klass Associates, Inc.
Chuck Klass graduated from Western Michigan University with a Bachelor's degree in pulp and paper technology and received a Master of Business Administration degree from Pace University. His 60+ years of paper industry experience include technical and operating positions with Hamilton Paper, Oxford Paper, Union Camp and Westvaco; editorial experience with Paper Trade Journal; technical service/sales/marketing management positions with Merck Chemical, Lockport Felt, Asten Group, and Inventing/BTG Coating Systems.

In 1986, he became a consultant to the paper industry specialized in coating, surface sizing and development of value-added papers; clients include producers of coated paper and paperboard worldwide and suppliers to the paper industry. He is a frequent guest lecturer at universities.

Mr. Klass is active with TAPPI and has served as Chairman of the Paper and Board Manufacturing Division, the Coating Process Committee, and on the TAPPI Board of Directors. He is a TAPPI Fellow and has received the Paper and Board Manufacturing Division Award, the Coating & Graphic Arts Division Leadership & Service Award, the TAPPI Distinguished Service Award and the TAPPI Gunnar Nicholson Gold Medal. He has numerous publications and has spoken at many TAPPI, CPPA, PIMA, and Smithers-PIRA Conferences, Seminars and Short Courses.

He also serves as Adjunct Professor of Paper and Chemical Engineering at Western Michigan University and teaches the “Principles and Practices of Coated Paper Manufacture” and “Advanced Papermaking” courses. He has also taught the TAPPI Short Courses “How to Market Effectively to the Pulp & Paper Industry”; “Introduction to Pigmented Coating Processes”; “Coated Paperboard”; “Blade Coating”; “Containerboard Manufacture”; “Improving Paper Machine Operation”; “Base Stock for Coating,” and “Sizing.” He has seven patents on papermaking and paper coating. His research interests include development of recyclable barrier coatings, digital printing papers, high graphic quality containerboard and lighter weight paper-based packaging. He was inducted into the Paper Industry International Hall of Fame in 2016.

Gordon Bugg, Kemira Oyj, Pulp & Paper Americas
Gordon brings to the course 40 years of experience in the paper and paperboard manufacturing and coating area. His first 20 years in the industry were with Mead (now WestRock), based at the Mahrt, Alabama mill where he served as Coating Operations Superintendent for the last seven years of his time with that organization. Upon leaving Mead, Gordon was a Coating Engineer with Eka Chemicals/AkzoNobel and in 2015 his group was part of an acquisition by Kemira Oyj.

He is currently a Senior Engineer for Kemira where he has global involvement in paper and paperboard coating development, grade development, converting and troubleshooting. Barrier coatings and curtain coater grade development are two areas of current focus. He combines an understanding of the theoretical principles of coating with many years of practical application experience. Gordon holds a Bachelors degree in Chemical Engineering from Auburn University, AL (1979) and a Masters in Strategic Studies from the Army War College (2004).

Gordon has been a member of TAPPI since 1981 and has been active at both the Local Section (going through the chairs of the Gulf Coast Local Section) and Division (Coating & Graphic Arts) levels. He served on the TAPPI Board of Directors (1999-2002) and is a TAPPI Fellow. He currently serves on a number of committees within the Coating & Graphic Arts Division. He has been an active volunteer instructor in TAPPI for many years and has assisted or served as instructor for more than 114 courses – to include TAPPI short courses, seminars, symposia and internal courses related to paper and paperboard coating.

Paralleling his career in the paper industry, Gordon retired from the US Army Reserves in 2009 after 30 years of service, holding the permanent rank of Colonel. His assignments included Command positions in Chemical, Special Forces and Logistics units, with overseas time in Korea as well as deployment to Iraq in 2004 as part of Operation Iraqi Freedom.

Dr. Brian Einsla, Dow Chemical Co.
Brian Einsla graduated from Virginia Tech with a PhD in Polymer Science and Engineering. He started at Dow in 2008 as an applications scientist in the Paper Coatings business. He has held roles in R&D and technical service where he has developed binders with improved strength, hollow sphere pigments for thermal insulation and opacity, and barrier materials for food packaging.

Meggan Hostetler-Schrock, Tate & Lyle
Meggan Hostetler-Schrock has nearly 15 years of experience in the industrial starch industry. She received her B.S. in Chemical Engineering from Purdue University in 1998. Meggan worked as a co-op student from 1994-1998 with Weyerhaeuser Company, supporting various technical projects through the Manufacturing Technology team in Federal Way, WA. Upon graduation, she spent her first years as a process engineer for Weyerhaeuser’s Liquid Packaging Operation in Longview, WA, working on projects focused on improvements in safety, quality, reliability, and cost. She then moved into a role as a Team Development Manager, working as a shift supervisor for several years on the machine. Finally, she transitioned into the role of Lab & Quality Manager.

She began her work with Tate & Lyle, a leading starch supplier to the paper industry, in 2006 as a Technical Service Engineer and then as Technical Manager, supporting the entire industrial starch business unit in the areas of paper (wet end, size press, coatings) and specialty (building materials, adhesives, other) applications. This team provides technical support to industrial customers, working with analytical resources, manufacturing, quality, and other areas of the business. The team is responsible for technical support and development in areas, such as lab studies and analyses (starch, wet end, coatings, adhesives, rheology modification, etc.), trial support, troubleshooting and problem resolution, as well as new product and applications development project pipeline for the Industrial business unit.

Dr. Anthony V. (Tony) Lyons, Paper Lyons LLC
Dr. Lyons has more than 36 years of experience in the areas of paper coating, paper finishing, and mineral pigments for paper coating, paper filling and other specialty applications. He received his Doctorate degree in Chemical Engineering from Lehigh University. He also holds a Bachelor and Master of Science degree in Chemical Engineering from the University at Buffalo.

His work experiences include time with Westvaco and Repap Technologies, Inc. He retired in 2017 from Imerys after 25 years with Imerys and established Paper Lyons LLC for the purpose of doing science and technology consulting. Tony is an adjunct professor at University of Maine and Western Michigan University. He has been an active member of TAPPI since 1985 and has volunteered for various leadership roles in TAPPI including election to the Board of Directors. He holds patents in coating pigments, coating applications, coated inkjet papers, agricultural applications and barrier coating.

Dr. Prakash Malla
Dr. Prakash Malla has 26 years of experience in mineral pigment development and processing as well as paper coating science and technology. He is currently the head of the R&D at Thiele Kaolin Company where he and his team are involved in improving and developing kaolin products and processes for improved paper coating and filler applications. He earned a Ph.D. in Clay Mineralogy and Clay Chemistry from Rutgers University. Additionally, he holds a Certificate in Mid-Management Program from Georgia Institute of Technology and an Executive Certificate in Management & Leadership from MIT. Prior to joining Thiele Kaolin Company, Dr. Malla was a Research Associate/Postdoctoral Fellow at the Materials Research Laboratory of Penn State University where he spent five years developing special types of dehumidifying nanoporous and high surface area materials from silica gels, zeolites, and pillared clays for natural gas-fired air-conditioning system. Dr. Malla has authored and co-authored of more than 40 technical papers including book chapters and holds 15 U.S. patents. 

Tim Bradley, Omya

Pam Hynnek, Valmet

Manoj Dixit, Domtar Inc.

Harald Döll, TSE Troller AG

Greg Welsch, Trinseo LLC


2021 Training Guide

Review the new 2021 Training Guide to learn more about the broad range of technical training resources from the TAPPI Academy.

Review rates at TAPPICon for discount information.

The TAPPI Advanced Coating Materials and Operations Course is co-located with TAPPICon 2021.

2021 Training Guide

Review the new 2021 Training Guide to learn more about the broad range of technical training resources from the TAPPI Academy.

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