Using Kaolin to Tune Key Performance Parameters in Future

Publication Ink Jet Grades

Ching Chen, Kamin LLCDoug Carter, Kamin LLC

Commercial High Speed Ink Jet Web Press

Evolution

SOHO Printer

Speed of Ink Jet Printers Transform From SOHO to Commercial Print Choice

• Speed: Modern commercial inkjet web presses are running at very high print speed. Approaching 1/3-1/2 of heatset web.- Up to 650fpm or 200mpm (>3x of Electrographic print ers)

• Web Width- Up to 30” wide ( close to conventional full web)

• Print heads for printing both sides in one pass- 2-8 units/press

• Inter-station NIR Drying Unit is often included in high speed ink jet press for multipurpose functions- Speed up ink drying rate- Improve Ink adhesion to the substrate

• More Ink Types are Used- Pigment Inks, pigmented inks, dye-based inks

Impacts of Ink Jet Technology Today

• Penetrating to Book Printing (publishers): - Publishers are opt for on demand printing because of potential saving on book inventory and

waste reduction for unsold volumes. Electronic publishing can supply readers with both paper and non-paper based books plus in-time editing capability.

- Books can be printed on uncoated paper monochrome printing and matte coated stocks for colors.- In-Line Binding capability makes Inkjet Printing a powerful alternative to conventional soft-cover

book printing

• Direct mailing (fulfillment service)- Ink jet can be a viable printing method for direct mailing application promoting sales and building

customer relationship. Coated stocks limitation giving many opportunities to EP at this moment.

• TransPromo Printing (Financial statement + Personalized Marketing )- TransPromo combines personalized marketing messages with must-read statements, invoices,

and other documents to help you accomplish two important, measurable results: increased revenue and retained customers

- Surface treated uncoated stocks are often used.

• TransEd Printing (Financial Statement + Education)- Another way to promote business relationship through education

• TransInfo Printing

“Ink Jet Technology, The Offset of Tomorrow”

Go Digital !

Digital Is Advancing Quite Rapidly andInk Jet Is Ready To Take In Sheetfed and Coldset

Print Run Length (# of copies)

10 1,000100 10,000 1,000,000100,000

PrintQuality

Low

Medium

High

Very High

Digital

Sheetfed

HSWO

CSWO

Gravure

Flexo

Impacts of Ink Jet Technology Tomorrow

• Expansion of Book Printing (publishers): - Publications can be printed on Gloss coated paper with full-color printing- In-Line Binding capability makes Inkjet Printing as a new integrating system a powerful

alternative to conventional publication printing

• Customized Catalogs- Digitized catalogs based on buying preferences. - Each print individualized

• Direct mailing (fulfillment service)- Ink jet will be a viable printing method for direct mailing application promoting sales and building

customer relation. Coated stocks of varying finishing and basis weight will be available for different applications.

- Personalized mail continues its growth.- Integrating printing system based upon ink jet as a core imaging unit.

• Packaging Printing- Labels- Display Boxes

What are remaining Barriers to Adoption of Ink Jet Technology?

• Coated Paper Substrate Availability- Technology Ownership/Partnership- Ink and Substrate Interaction- Jetting Methods (CIJ, DOD…)

• State of Uncertainty in Paper Industry• State of Uncertainty in Business Environment (# of Installations)• Technology Impacts From Computer Industry

Can’t solve all the Uncertainty but Can address Making sure Paper is not the Barrier

“Can not score if you don’t have the ball”.

Where are the Opportunities

Sheet Gloss

Coa

t Wei

ght

gsm

2

8

6

4

14

12

10

Matte 20 30 40 50 60 70 80 90 100

Current Ink Jet Paper Availability

Photo Glossy

Gap

Opportunities in Ink Jet Match Current Offset Grades Produced. But can they be used?

Do Current Coated Paper Grades Work?

No… Why Not?• Poor Ink Densities

- A Typical formulation Based upon (80/20 GCC/Clay; 10-12 Parts of SB/SBA/Starch binders)

- Dm=0.80; Dc=0.88; Dy=0.64; Dk=1.65

• Severe Non-Uniformity in Solid Print Colors or Print Mottle

• Poor Resolution due to ink bleeds or Slow Ink Drying Rate• Narrow Color Gamut

• Poor Permanence

How do we Address these Challenges?

The Concept Coating Using Specialty Fine Kaolin

• Publication Gloss Ink Jet Grade Formulation - Utilize High Standard Carbonate To maintain cost position- Utilize Specialty fine kaolin

• Generates Gloss and Coater Runnability • Ink Interactive to control ink performance.

- Uses specific latex binder approach for efficient high solids coating.

• Conventional Blade Coating • Coat Weight: 6-12 gsm• Formulated to Exhibit Water Fastness• Formulated to Exhibit Wet Rub Resistance

Why Customize Kaolin?• Lowest Cost Option for the Overall Coating

- Bulk of Coating is Carbonate • Customizing this pigment makes any changes here have higher cost impact overall.

• Bulk carbonate provides some key attributes in terms of optical properties and dewatering that need to be maintained.

- Kaolin’s surface chemistry is a platform for modification• Amphoteric nature gives good platform to bind different chemicals.

• Changing nature of surface as function of pH adds to ability to modify

• In High carbonate coatings Fine Kaolin is at the surface- Fine Kaolin migrates to the top of the coating surface where it can have the

largest impact on:• Glossing Properties

• Surface Smoothness• And Ink Interaction – we can leverage this!

HP950C Printed on Current Coated Paper

Concept CoatingUse of Treated Fine Particle KaolinBinder: LatexCoat Weight: 10gsm

Standard Offset Gloss PaperPigment: 80/20 Std GCC/ Std Fine KaolinBinder: LatexCoat Weight: 10gsm

Using Treated Clays as a Performance EnhancerDoes it Work?

Using Treated Fine Kaolin as a Performance Enhancer

Paper Gloss Yellow Magenta Cyan Black Uniformity Water Fastness Wet RubConcept Coating 68 0.82 1.18 1.12 1.62 Smooth Good GoodCurrent Offset Coated Gloss 72 0.64 0.80 0.88 1.65 Mottling Poor Poor

Solid Ink Density Permanence

Conclusions• Concept of Using Treated Kaolin Works to Make Offset

Grades Viable in Ink Jet Applications! - There Is An Opportunity in Producing Various Publication

Coated Gloss Ink Jet Paper Grades.- Best Cost Position for These Gloss Coated Publication

Paper Will be Based Best Coating Practices in Offset Coatings but with specific “tweaks”.

- Balancing the Ink Jet Print Performance Requirements Can Be Achieved Using Specialty Fine Kaolin As the Additive Pigment that Maintains High Gloss and Coated Runnabilitybut achieves targeted properties for Ink Jet.

Critical to Success is Not Just a good Pigment…it is the Technology Partnership Between Paper Producer and

Their Suppliers.

This Partnership will make the Future a Reality

Conclusions