EFFECT OF BIO-POLYMER LATEX ON COATED PAPER Submitted by : N. Srikanth Date : 18 -5-2009.

EFFECT OF BIO-POLYMER LATEX ON COATED PAPER

Submitted by : N. SrikanthDate : 18 -5-2009

Topics 1. Overview 2. Objectives3. Methodology4. Results5. Conclusion 6. Recommendations 7. Question & Answer

Submitted by : N. Srikanth

Why is Paper Coated?

Overview


Why is Paper Coated?1. Printability

- Improved Smoothness

- Uniform Coating

- Better Ink Receptivity

2. Visual Properties

- Improved Brightness

- Better Opacity and Gloss

3. Functionality- Reduction in ink consumption

- Better Glue ability


Different Coating methods

Base Sheet

Coating

Base Sheet

Coating

Level Coating - Good smoothness

Contour Coating- Better Coverage


Coating Components

• Pigment (85-95 wt %)

(GCC and Clay)

• Binder (5-15%)

• Water• Sodium Hydroxide• Lubricant• Defoamer

• Thickener (Rheology Modifier)• Dye• Optical Brightener (OBA)• Cross-linker• Dispersant


Synthetic Binders• Different types of Synthetic polymers

– Styrene butadiene– Polyvinyl acetate– Vinyl acrylic– Acrylic latex– Polyvinyl alcohol

• Synthetic binders helps to improve final sheet properties like– Gloss – Smoothness– Printability


What is Biopolymer latex

Biopolymer NanoparticlesEx. Native Starch Granules

Effective surface>200 m2/g (est.)

30 µm

200 nm

Size reduced300-600x


Advantage of Biopolymer latex • Effect on Environment

- Substitute to synthetic latex- Reduced GHG emission- Clean and lean manufacturing - Satellite production plant close to customer- No volatile organic compound- Reduced carbon foot print- Easy to start the production process

• Addition of Bio polymer latex improves final sheet property like,

- Increase in dry pick strength, - Reduces print mottle, - Increase in pore volume, good glue ability. - Increase in paper stiffness.


Preparation of Biopolymer latex

Submitted by : N. SrikanthSource :Tappi paper 360 magazine.

Water-Swollen, CrosslinkedBiopolymer Core: V(Core)

Bound and AdsorbedBiopolymer Shell: V(Shell)

The Hypothesized Structure of a Water-Swollen, Crosslinked Biopolymer Nanoparticle

The biopolymer latex has a small hairy water soluble starch polymer in the surface , sterically stabilized protective colloidal layer which is cross linked with insoulblizer like glyoxal or AZC.


Dispersion range of latexParticle Size Measurements

10 nm 100 nm 1000 nm1 µm

10,000 nm10 µm

100,000 nm100 µm

Bio- polymer range of emulsions

Bio- polymer in Dry paper coat

PV

Ac

SB R Sta

rch


Film formation of Bio polymer latex

Free-FlowingDispersion

Entanglement & in-solubilizationat the particle interfaces

Drying/Compaction

Gelation/Immobilization

Water liberates, but biopolymer cores do not collapse and form “nano-cellular foam-like” film, yielding air

voids

Particle Deformation & Further Coalescence

ConsolidationWith Partial Collapse

Aqueous dispersion of water-swollen biopolymer nano-particles

Stiff water-swollen cross-linked biopolymer nano-particles do not collapse much during film formation. Consequently, film shrinkage is much less than starch and more like S/B latex, yielding better gloss and improved opacity under optimized calendering conditions.


Objectives


1) Replacing Synthetic binder SB and SA latex with Bio polymer latex LA 40 in an increment of 25% up to 100% ,while keeping other coating receipe components constant.

2) Comparing properties of coating color, surface and printing properties of coated paper i.e. Control formulation vs. combination of SB ,SA latex and Bio polymer latex formulation.


Methodology


Test formulationReference(Control Sample )

Description units SB Latex SA latex Bio latex

Pigment Parts 100 100 100

synthetic latex Parts 12 12 12

Bio polymer latex Parts 0 0 0

CMC Parts 0.5 0.5 0

Total Parts 112.5 112.5 112

Set #1 ( SB latex +Bio polymer latex)

Description units #1 #2 #3


synthetic latex(styrene butadiene) Parts 9 6 3


CMC Parts 0.5 0.5 0.5

Total Parts 112.5 112.5 112.5

Set #2 ( SA Latex +Bio Polymer latex)

Description units #1 #2 #3


synthetic latex(styrene acrylate) Parts 9 6 3


CMC Parts 0.5 0.5 0.5

Total Parts 112.5 112.5 112.5


Calculation of chemicals dosage as per recipes

Make down of recipe

Dispersion of chemical

Chemical preparation

Check Printing properties.

Testing of coated paper 1. Coat weight2. Brightness3. opacity4. IGT pick5. PPS6. Porosity7. caliper8. Gloss

Drying of coated paper

Test for base paper

1. Basis weight2. Moisture3. Ash %4. Thickness5. Density6. Porosity7. PPS8. Tensile9. Brightness10. opacity

Additive addition1. Synthetic binder2. Lubricant.3. OBA

Preparation of binder/Co binder

1.CMC .(10% solution)2.Ready to use Bio-polymer latex (40% solution)

Making coated paper.

Testing of coating color.1. pH value.2. Solids content3. Viscosity (cps)4. Water retention

Chemical testing1. pH value2. Solids content3. moisture4. Viscosity5. Appearance

Super calendering of coated paper

Testing of coated paper

1. Brightness2. Opacity3. IGT pick4. PPS 5. Porosity6. Caliper7. Gloss

Target coat weight 11 +/- 0.5 gsm

Testing of coated paper

1. Print Gloss2. Wet pick3. Wet Repellence4. Set off5. ISIT6.Print density


Results


Water retention of coating color

Water Retention Value of coating color

0

50

100

150

200

250

300

350

12 parts (100%) 9 latex /3 Bio parts(25%sub)

6/6 pph latex/Bio (50%sub)

3 latex /9 Bio parts(75%sub)

Ratio of binder

g/m

2 .

Biopolymer LA 40 SBR HPT 129 Acronal HPT 134

SC Paper PPS @ 160 kN/m

0.88

0.9

0.92

0.94

0.96

0.98

1

1.02

1.04

1.06




Ratio of binder

µm

Bio-polymer- LA 40 CAL Acronal HPT 134 Cal SBR HPT 129

Uncalendered Paper K& N Ink Receptivity

0

5

10

15

20

25




Ratio of Binder

%

Bio-polymer- LA 40 UNCal SBR HPT 129 UN CAL Acrylate HPT 134

Increased water retention by 50% to 100% Submitted by : N. Srikanth

Bio polymer and SB latex

Wet Void Volume - coating colorWet void volume of coating color

0

10

20

30

40

50

12 parts (100%) 9 latex /3 Bioparts(25% sub)


3 latex /9 Bioparts(75% sub)

Ratio of binder

W.V

.V

Biopolymer LA 40 Acronal HPT 134 SBR HPT 129

Increase in Wet void volume value by 6% to 25%.


Viscosity of coating color

Viscosity of coating color.

0

500

1000

1500

2000

2500

3000


6/6 pph latex/Bio(50% sub)


Ratio of binder

cps

Biopolymer LA 40 SBR HPT 129 Acronal HPT 134

Increase in viscosity of color by 50%- 100% . Submitted by : N. Srikanth

PPS roughness of SC paper SC Paper PPS @ 160 kN/m

0.880.9

0.920.940.960.98

11.021.041.06


6/6 pph latex/Bio(50% sub)


Ratio of binder

Bio-polymer- LA 40 CAL Acronal HPT 134 Cal SBR HPT 129

Marginal increase in PPS value by 5% - 10% Submitted by : N. Srikanth

Brightness of SC paper

Super Calendered Paper Brightness

80

81

82

83

84

85

86

87

88

89

90

12 parts (100%) 9 latex /3 Bio parts(25% sub) 6/6 pph latex/Bio (50% sub) 3 latex /9 Bio parts(75% sub)Ratio of Binder

Bio-polymer- LA 40 Cal SBR HPT 129 CAL Acronal HPT 134

No difference in brightness value of coated paper


Opacity of SC paper

No or slight difference in the opacity value of the paper

Super Calendered Paper Opacity

90

91

92

93

94

95

96




Ratio of binder

%

Bio-polymer- LA 40 Cal SBR HPT 129 CAL Acronal HPT 134


Dry pick of coated paper

Dry pick of coated paper(MD)

0

0.5

1

1.5

2

2.5

3

3.5

4

4.5

m/s

uncalendered

calendered

Increase in Dry pick strength by 40%.Submitted by : N. Srikanth

Delta gloss of printed paper

Increase in Delta gloss (print snap) by 50%

Delta Gloss

02468

10121416

(A) 1

2 pp

hSB

R(1

00%

),

(B)1

2pp

h SA

(100

%),

(C

)12

pph

LA40

(100

%),

(A) 9

/3 p

phSB

R/L

A40(

25%

sub)

(B

) 6/6

pph

SBR

/LA4

0(50

%su

b),

(

C) 3

/9 p

phSB

R/L

A40(

75%

sub)

,

(A) 9

/3 p

phSA

/LA4

0(25

%su

b),

(

B) 6

/6 p

phSA

/LA4

0(50

%su

b),

( C

) 3/9

pph

SA/L

A40(

75%

sub)

%


Customer Savings Reference #1 #2 #3

Pigment Parts 100 100 100 100

synthetic latex Parts 12 9 6 3

Bio polymer latex Parts 0 3 6 9

CMC Parts 1 0.5 0.2 0

Total Parts 113 112.5 112.2 112

Basepaper gsm 40 40 40 40

Coat weight gsm 20 20 20 20

Total gsm 60 60 60 60

MT/yr Total binder Cost (US$ Million)

Paper production 300,000 $23.40 $22 $21.10 $20.30

Estimated Annual savings US $M $1.40 $2.30 $3.00

% 6% 11% 15%

Bio latex Substitution level 0% 24% 49% 75%

Cost saving Sheet

Potential annual cost saving is from 6% to 15%.Submitted by : N. Srikanth

Environment consideration

Fossil content 1%

Mean Bio based Result: 1* as per ASTM D 6866 Proportions Bio based Vs Fossil Based indicated by 14 C content for SB latex

Mean Bio based Result: 99* as per ASTM D 6866 Proportions Bio based Vs Fossil Based indicated by 14 C content for Bio latex

Bio basedcontent 99%

Bio based content 1%

Fossil content 99%

For every 1 million lb of SB /SA latex3.3 million pounds (1,515 metric tons) of CO2 emissions

Biopolymer 37.5% substitution level of Industry wide would reduce CO2 emissions by 2.27 MMT equating to 600,000 cars off the road


Features Benefits1 Substitute for latex binder Similar performance in coating colors

2 Requires no cooking Energy (steam) and labor savings

3 Modified biopolymer from starch Carbon neutral and Renewable resource

4 Lower latex cost Significant annual savings, Price stability, not linked to varying petroleum prices

5 Viscosity & ultra-high shear rheology = synthetic latex

Simple adjustment of existing coating recipe – similar or better runnability

6 Reduce rheological modifier Additional potential saving

7 Available dry or liquid Freight savings & formulation flexibility

8 Recyclability Reduced batch time and saving in power.

9 Effluent system No shock load and good nutrient for the system.

Benefits of Bio polymer latex


Conclusion


• Increased water retention by 50% to 100%

• Increase in viscosity of color by 50%- 100%. • Marginal increase in PPS value by 5% - 10%.

• Increase in Delta gloss (print snap) by 50%

• Increase in Dry pick strength by 40%.

• Increase in Wet void volume value by 6% to 25%.

• No difference in brightness value of coated paper• Potential annual cost saving is from 6% to 15%.


Conclusion

Properties of coating color Bio-polymer Latex LA 40 Synthetic Latex(SB,SA) LA40 /Synthetic Latexes(SB/SA)

Ease of Formulation

Water Retention

Air volume %

Density

Sediment volume

Viscosity

Properties of coated paper Bio-polymer Latex LA 40 Synthetic Latex(SB,SA) LA40 /Synthetic Latexes(SB/SA)

Gloss

Porosity

PPS

Thickness

porevolume

K&N

Dry Strength

Wet Strength

wet repellence

Print Gloss

Brightness w/o OBA

Print Density

Opacity

Ink tack rise

Increase No Change Decrease Submitted by : N. Srikanth

Summary

Recommendations


1) In all coating mill, all pre-coat formulation 100% Bio polymer latex LA 40 can be substituted in place of Synthetic binder SB and SA latex

2) In top coating formulation 25 -50% Bio polymer latex LA-40 can be substituted in place of synthetic SB and SA latex.


Question ???

&

Answer !!!


Thanks

Dr. Mousa Nazhad, Asian Institute of Technology.

Dr.Esa Lehtinen, Asian Institute of Technology

Dr.Esa Viljakainen, Asian Institute of technology.

Dr.Robert Hill , IMERYS Ltd, UK.

Mr.Edwald Beivi , UPM Research centre, Changzhou ,China.

Ms.Zhang Homing , UPM Research center Changzhou, China.

Dr.H.Komoldin, Advanced Agro limited. Thailand.

Ms.Daroung Inthong, Siam Modified Starch co, Ltd.


EFFECT OF BIO-POLYMER LATEX ON COATED PAPER Submitted by : N. Srikanth Date : 18 -5-2009.

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Transcript of EFFECT OF BIO-POLYMER LATEX ON COATED PAPER Submitted by : N. Srikanth Date : 18 -5-2009.