Advanced Coating Materials and Operations Course

Charlotte, NC
Saturday, April 30, 2022 to Sunday, May 01, 2022

Co-located with TAPPICon 2022

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 and 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.

For questions please contact us at [email protected]

Course Co-Chairs: Lokendra Pal, NC State and Martti Tuomisto, Advanced Dynamics Corp.

Dr. Lokendra Pal is an Associate Professor in theLokendra Pal.jpg Department of Forest Biomaterials at North Carolina State University, Raleigh, USA. He has over 14 years of professional experience in managing and collaborating with industrial partners worldwide. Before joining NC State, he spent 9 years working with Hewlett-Packard Company leading new product research and development programs. Dr. Pal has filed 38 patent applications and been granted 23 patents.

He obtained his Ph.D. in Paper and Imaging Science and Engineering from Western Michigan University, Kalamazoo, MI. He is a certified Lean Six Sigma (LSS) Black Belt. Dr. Pal research group is focused on developing sustainable and functional bioproducts, delivering top-class hygiene, smart packaging, and flexible electronics/3D printable materials and products that benefit society as well as the environment.


Martti Tuomisto is widely recognized as a leading technical1517782138238.jpg expert in papermaking processes, paper mill conversions from printing papers to packaging & specialties, paper machine technology from the wet end to the dry end - plus in coating, calendering, winding, and roll handling & wrapping. Successful record in paper machinery business and product management, papermaking process & paper grade development, technical sales / customer communications, sales contract and mill performance negotiations, as well as process engineering & application engineering.

Specialties: Papermaking processes, paper machine technology, paper quality development, paper mill conversions, coating, calendering, paper roll handling & wrapping, business management, sales contract negotiations, technical customer communications & technical presentations, mentoring and public speaking, and team leadership

Chuck Klass
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. He has 7 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
Gordon has more than 38 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 with Eka Chemicals/AkzoNobel and 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. He holds a Bachelors in Chemical Engineering from Auburn University, AL (1979) and a Masters in Strategic Studies from the Army War College (2004).

Brian Einsla, Dow Chemical Co.
Brian 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
Meggan Hostetler-Schrock has more than 12 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 on the liquid packaging board machine 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 Service Manager, supporting the entire Industrial Starch business unit in the areas of paper & packaging (wet end, size press, coatings) and specialty (building materials, adhesives, other) applications.

Tony Lyons, Paper Lyons LLC
Lyons received his doctorate degree in Chemical Engineering from Lehigh University, and has more than 36 years of experience in fluid mechanics, paper coating, paper finishing, and mineral pigments. He worked with Westvaco and Repap Technologies, and retired in 2017 from Imerys after 25 years. He then established Paper Lyons LLC for the purpose of doing science and technology consulting. Lyons is an adjunct professor at University of Maine and Western Michigan University. An active TAPPI member since 1985, Lyons has held various leadership roles in TAPPI including on the board of directors.

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 5 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


DAY 1.  (8:00 am to 6:00pm)

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
Functional coating additives– Gordon Bugg, Kemira


DAY 2. (7:30 AM to 4:00 PM)

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.) – Vesa Kukkamo, ACA Systems

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
Other possible new materials? (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.) – (speaker?)

3:15­ 3:30 PM Closing & Final Remarks

4:00-6:00PM Hagemeyer Happy hour

IDCON Shutdown Turnaround Optimization Process

Tuesday, September 28, 2021

This three-day course presented through a TAPPI partnership teaches you how to stay on budget and minimize downtime through IDCON's six-step process that focuses on countdown actions, tools, and resource optimization.
Learn More

BLRBAC Fall Meeting 2021

Wednesday, October 06, 2021

The Black Liquor Recovery Boiler Advisory Committee (BLRBAC) is holding its annual Fall Meeting, October 6, as a virtual event to share knowledge and maintain guidelines to help facilitate the safe, reliable operation of black liquor recovery boilers.
Learn More

Kraft Recovery Operations Course

Monday, January 10, 2022

One of TAPPI's highest rated, longest running events! You'll learn ways to improve pulp production efficiency, minimize operating costs and reduce environmental impact. This course is designed for pulp mill operations personnel.
Learn More