Cham Paper Group

Mark Gooseman

Cham Paper Group (UK) LtdRoyal Victoria HouseTunbridge WellsKent TN2 5JUEnglandgooseman.mark@cham-group.comwww.champaper.com

PaperSpeciality or Commodityand the New Challenges

An overview of the Market(As a papermaker‘s view).

Mark R Gooseman

Cham Paper Group

• Introduction to Cham Paper Group

• Are Metallising papers a commodity?

• Base Papers for metallising – what is the difference?

• Market segments of metallised papers and their technical requirements

• Future demands for metallising base papers

• Risk for metallising base papers

Overview

Cham

The Cham Paper Group

Tenero

Hunsfos

Condino

Carmignano

Flexible Packaging & TechnicalPapers

Pressure Sensitive Base Papers

Technical Paper Grades

Sales 2004 – tonnesProduct Range

Other Papers

13%

Flexible

Packaging

24%

Pressure

Sensitive

30%

Technical

Grades

33%

Sales 2004 – tonnes: % per region

Italy

10%

Germany

24%

United Kingdom

10%

France

3%

Netherlands

10%

Asia

8%Rest World

3%

Switzerland

2%

Spain

7%

Norway

1%

Rest Europe

7%

North/-South

America

11%

Belgium

4%

SummarySummary

uu 265 000 265 000 tonnes capacity fromtonnes capacity from HiHi--TechTech. . machinesmachines

uu 8 Paper Machines (MF and MG)8 Paper Machines (MF and MG)

uu 4 Off4 Off--line line Coaters Coaters

uu 2 On2 On--line line CoatersCoaters

uu SupercalendersSupercalenders, , MachineMachine calenderscalenders, , WindersWinders//SlittersSlitters

uu CoatedCoated and and uncoated Specialtyuncoated Specialty Papers Papers fromfrom 1717--200 g/m200 g/m22

uu CompleteComplete ProductProduct Range Range for the variousfor the various Market Market SectorsSectors

uu International International sales company sales company and Agency and Agency networknetwork

• How do we begin to differentiate “commodity” from “speciality” ?

– Production Capacity

– Added value

– Added technical properties

– Tailor made papers

– End user understanding

Market Requirements of MetallizedPapers

RAW MATERIALSAluminiumPapersLacquers

Commercial Metallizing

PackagingSecurityGiftwrapTobaccoLabel

Barrier Properties Image

Packaging Marketing

Functionality ImageValue

Creation Security

Paper Ingredients

Natural FibresFillers

Water

Additives

A typical Premium Clay Coated Paper for Metallizing ApplicationsCLAY COATING - trimmed for :• Good Lacquering and Metallizing Properties• High Surface Smoothness

(double coating plus calendering)

REVERSE SIDE COATING (optional) - trimmed for :• Optimal Rehumidification• Lay Flat Properties• Specific Smoothness Requirements•Possible Barrier Treatments

BASE PAPER - trimmed for :• High Internal Bond• Lay Flat Properties• Dimensional Stability• Controlled moisture• Low taint and odours• Stiffness•Good die-cutting

Refinements

„One change will always precipate another!“

• Pulp Mix

• Refining

• Additives

• Formation

• Calendering

• Sizing

• Coating

• Lacquering

Paper Making: Fibres' Characteristics

ca. 3,2 mm longca. 0,035 mm wide(pine, spruce)

ca. 1,9 mm longca. 0,022 mm wide(eucalyptus,birch)

Conifers groundwood(fibre bundles)

Pine Spruce

BirchEucalyptus

Long- / short fibre mix

The right choice of fibremix to achieve required product characteristics = determining factor in the art of paper making

Compromise ofStrengthFlexibilityPrintabilityOpacity

Sheet formationLayflatproperties

Cost

Small particles from inorganic substances (chalk or China-clay), which fill areas between fibres.

Fillers

The higher the particle weight, the more filler is washed out during sheet formation. It is therefore difficult to reach a high filler content in the paper.

Fillers do not form any bond with fibres.

Auxiliary Materials and Additives

Paper characteristics can be modified with the addition of chemicals

Important additives

Sizing agents

Wet strength resins

Optical brighteners

uu Scope:– Improve writeability/wetability

– Improve coating bond to surface of base paper through uniform binder absorption into the sheet structure and control of water retention

Ø Surface sizing ð size press

Ø Stock sizing

Sizing of Paper

Water absorption

unsized sized

Wet Strength Resins

• The internal hydrogen bonding of the untreated paper is destroyed after soaking in water. The paper falls apart.

• This can be avoided by adding wet strength resins, thus in wet conditions a certain level of strength can be reached.

• Furthermore, strength and stiffness can be slightly increased.

• The absorption of the paper remains just as it was.

When impregnated with water, hydrogen bonds are dissolved.

By adding wet strength resins, strength in wet conditions can be substantially improved.

Wet Strength Papers

Water content

100% tensile strength

5%

50%

20%

0

without

with wet strength agent

saturated

Assessment of machine direction

MD

MD

CD

MD = Machine Direction

CD = Cross Direction

1st step: Coating

• Pigments (clay, calciumcarbonate, titandioxide)

• Binders (synthetic latex, natural binders like starch)

• Modifiers (improve runnability on coating machine)

• Additives (optical brightener, dye pigments)

What is a Clay Coated Paper?

Top coating Precoating

Reverse side treatment

Base paper

A high-quality kraft paper;mostly douple sided coated,

often (super)calendered

Some coating pigments

ChinaclayChinaclay CCalalcciumiumccarbonatarbonatee

Coatings' Bond Agents

They are responsible for:Picking resistanceAbsorbencyVarnishability

Coating absorptionSealabilityand partly for the paper’s gloss

Bond agents connect the pigment parts with the carrier(base) paper – similar effect to glue.

CC LATEXC STARCHC PVA

Optical Brighteners

Transformation of the invisible UV-light into visible blue-light

• Increase ofbrightness

• Shift from a yellow to a bluish tone

2nd step: Calendering

• Provides coated paper with a high gloss level

• Excellent smoothness

Satinating Calender

GlossmeterGlossmeter

Photo cellPhoto cell

KKüüstersstersrollroll

Steel rollSteel roll

Paper Paper rollroll

Effect finishing on paper properties

LowerHighHighTear strength resistance

LowerHighVery highBulk

LowerHighHighAir permeability

LowerHighHighOpacity

LowerHighVery highStiffness

Very smoothSmoothRoughSmoothness wire side

Very smoothRoughRoughSmoothness felt side

Super

calendered

Machine glazed (1side)

Machine finished

3rd step: Lacquering

• Nitrocellulose, acrylic (some cross linked for beer labels), vinylacetate

• Mostly gravure (reverse gravure)

• Now up to 1200 m/min.

Metallized Labels

Beer labels

• High gloss after metallising

• Alkali resistance

• Ink retention

• Dye cutting properties

• Runnability on beer labelling machines

• Gravure and offset printing

• Layflat properties

• Dimensional stability

Labelcar WS HG, 68 g/mLabelcar WS HG, 68 g/m22

• One side double coated Kraft paper with reverse side treatment

• Wet strength and alkali-resistant

• Excellent properties for metallization

• Excellent surface with high gloss (Gloss Lehmann 75o

WS TAPPI T480 86 %)

• Good results in flexo, rotogravure and offset printing

• Application: High gloss labels for returnable bottles, meeting requirements of the beer industry

Top coat

Pre-coat

Kraft paper

Reverse

Future Trends / Label Papers

• Higher gloss

• Cost reduction

• Combi papers (offset, gravure, bottle neck labelling)

• Better layflat properties and dimensional stability

• Rougher rear side

• Higher ink retention (vision of twice useable labels - recycling)

• Higher speed on bottling machines (40`000 to 60`000 bottles per hour, new 70`000 per hour)

• Special labels (grease proofed papers)

• Special Finishes

Challenges for metallised labels

• Metalure inks !!!

• White labels

• Self adhesive labels (might also be metallised)

• Film labels, direct printing on bottles

Chances for metallised labels

• Achieving a higher difference in gloss level between metallised paper and metalure printed labels!

• Flexibility

Tobacco Products

Inner liner requirements

• High gloss and smoothness

• Low odour and VOC, high purity

• Toxicological properties

• Runnability on cigarette machines

• Runnability on coater and metallizer (low substance)

Innerliner Plus

• One side double coated Kraft paper

• High volume

• Optimal for watery laquers

• No addition of OBA

• Odourless and taint free

• Excellent properties for metallization

• Application. Metallized innerliner for cigarette packs

• Thickness DIN 53105 T1 45 micron Innerliner Plus

• (Innerliner Elite 50 micron)

Top coat

Pre-coat

Kraft paper

Inner liner paper – future trends

• Higher gloss

• Suitable for high-speed cigarette machines

• Lower volatiles

• Increase in water based lacquer systems

• Higher speed on lacquering machines

• Holograms in inner liners

• Security items

• Cost reduction

Challenges for Inner liner

• Metalure inks: but not as serious as on label papers

• Returning to aluminium foils

• New laws that reduce cigarette consumption

Stable requirements expected

Metallized Flexible Packaging

Confectionary

Packaging is changing

Packaging is changing

è

è

è

Giftwrap

Gift wrap / specialities

• High gloss level and high smoothness

• Good mechanical properties

• Properties according to requirements (grease proofed papers)

• High Strength and Bulk

Risks:

• Fashion tendencies

Gift wrap: future trends

• Lower costs

• Higher gloss level and smoothness

• Lower substances with same mechanical strengths

Key Trends

u Consolidation

uLabel Printers

uFlexible Packaging converters

uLaminating

uPressure Sensitive

uTobacco Companies

uFood Producers

Tobacco

Austria Tabac

JTI

Gallaher

Bulgartabac

Tabacalera

BAT

ETI

AltadisReemtsma

Imperial

Philip MorrisSeita Tekel

Tobacco

Austria Tabac

JTI

Gallaher

Bulgartabac

Tabacalera

BAT

ETI

AltadisReemtsma

Imperial

Philip MorrisSeita Tekel

Tobacco

Austria Tabac

JTI

Gallaher

Bulgartabac ??

Tabacalera

BAT

ETI

AltadisReemtsma

Imperial

Philip MorrisSeita Tekel ??

Tobacco

Austria Tabac

JTI

Gallaher /Austria Tabac

Bulgartabac ??

Tabacalera

BAT

ETI

AltadisReemtsma

Imperial /Reemtsma

Philip MorrisSeita Tekel

Flexible Packaging

AMCOR

Sopal

Danisco

Hueck-Folien

PKL

Gascogne

Rexam

Pawag

Tiech

Sopal

Pechiney

Alcan

ConstantiaVAW

Flexible Packaging

Sopal

Danisco

Hueck-Folien

PKL

Gascogne

Rexam

Pawag

Tiech

Sopal

PechineyConstantia

VAW

United Flexible

AMCOR

Alcan / Novelis

How can we develop new trends and applications?u Look at Geographical Regions

Ø Tobacco

Ø EMA / AIMCAL

ØUtilise the new structure to

ØCreate new „joint markets

ØBe creative through „Workshop“

ØAdd Value

Summary

• New challenges in wet strength beer label business

• Rather a stable market in the Cigarette Industry

• Printing / Packing / Conversion speeds

• Changing requirements / trends

• Cost Pressure

The right paper and The right paper and enduseenduse

Metallizing Paper :The Future!

We need to work together to ensure that what is aspeciality material – and make no mistake,

it is a speciality – remains so!

“Use your partners strengths”

Thank You!

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