Paper Conference and Trade Show 2010 (PaperCon 2010)

Atlanta, Georgia, USA 2-5 May 2010 Volume 1 of 4

ISBN: 978-1-61738-789-0

Printed from e-media with permission by: Curran Associates, Inc. 57 Morehouse Lane Red Hook, NY 12571

Some format issues inherent in the e-media version may also appear in this print version.

Copyright© (2010) by the TAPPI Press All rights reserved. Printed by Curran Associates, Inc. (2010) For permission requests, please contact the TAPPI Press at the address below. TAPPI Press 15 Technology Parkway South Norcross, Georgia 30092

Phone: (800) 332-8686 Fax: (770) 209-7206 [email protected]

Additional copies of this publication are available from: Curran Associates, Inc. 57 Morehouse Lane Red Hook, NY 12571 USA Phone: 845-758-0400 Fax: 845-758-2634 Email: [email protected] Web: www.proceedings.com

TABLE OF CONTENTS VOLUME 1 SESSION 1: WELCOME SESSION AND COATING KEYNOTE It Takes a Village - Starbuck's Quest for the Recyclable Cup ........................................................................................... 1 Jim Hanna

SESSION 2: OPENING SESSION AND KEYNOTE ADDRESS Magazine Publishing – Looking Forward............................................................................................................................ 2 Nina B. Link

SESSION 4: NEW TECHNOLOGY SHOWCASE 1 The Integrated Knowledge of Producing an ASME Certified Dryer Cylinder ................................................................ 3 Jack Chen

Nalco’s Crepe Analysis Tool Box........................................................................................................................................ 32 Larry Bonday

Using Thermal Spray vs. Weld Overlay in Batch Digesters............................................................................................. 44 Chad Wagner

Simultaneous TrumpJet® Flash Mixing of Starch and Filler Will Cut Costs and Save Environment ......................... 50 Jouni Matula

Kytola Oval Gear System.................................................................................................................................................... 63 Aappo Roos, Bert Hogendoorn, Philip Callahan

The Leader in Safe and Dependable Rail and Freight Car Door Openers ..................................................................... 75 Arnold Huelsmann

OpTiBlend Analysis with the HiRes Fiber Quality Analyzer .......................................................................................... 83 Cathy Joss

School Without Walls - On-line Pulp and Paper Training Solutions .............................................................................. 99 Don Defreese

L&W Fiber Quality Transmitter - Continuous Inline Pulp Measurement................................................................... 114 Per-Olof Warendh

New Biotechnology for Paper Machine Boilouts............................................................................................................. 137 Phil Hoekstra

New Green Chemistry for Water Clarification............................................................................................................... 156 Rosy Covarrubias

SESSION 6: COATING MATERIALS CIG LUNCH & LEARN Update & Overview on Mottle in Offset Printing ........................................................................................................... 168 Dave Smith

SESSION 9: CARBON MANAGEMENT I Carbon Management in the Context of Sustainability ................................................................................................... 213 George Weyerhaeuser Jr.

SESSION 10: ROUNDTABLE: GOING GREEN – WHAT DOES IT MEAN FOR PAPERMAKING? Community Perceptions of Green .................................................................................................................................... 214 Linda Robertson

Collecting Foodservice Packaging for Pick-Up with Old Corrugated Cardboard....................................................... 222 Annie White

SESSION 11: PAPERMAKING INNOVATIONS KICK-OFF Development of Papermaking Technology ...................................................................................................................... 223 Dick Reese

SESSION 12: PAPER MACHINE SENSORS TUTORIAL Paper Machine Sensors Tutorial ...................................................................................................................................... 263 Kerry Figiel, John C. Gill, Ross Machattie, Seyhan Nuyan, Steven Sturm, Jack Tippett

Paper Machine Quality Control Systems (QCS)............................................................................................................. 266 Kerry Figiel

SESSION 13: COATING SUSTAINABILITY / ENERGY SAVINGS State-Of-The-Art Developments to Save Energy in Coating Drying............................................................................. 321 Bob Bates

Improving Drying Efficiency of the Coating Process by Optimal Use of Energy from Infrared Dryers ................... 332 Geert Dumortier

Life Cycle Sustainability Assessment of Paper and Packaging...................................................................................... 377 Olivier Jolliet

SESSION 14: COATING STRUCTURE Sequential Imbibition of Polar and Non-Polar Liquids into Compacted Calcium Carbonate Coating Structures ........................................................................................................................................................................... 378 Cathy J. Ridgway, Joachim Schoelkopf, Patrick A. C. Gane

The Influence of Application System on the Structure of Coating Layer ..................................................................... 432 Pekka Salminen, Arthas Yang, Johannes Kritzinger, Wolfgang Bauer, Janet Preston

Setting Rates of Oil-Resin Systems................................................................................................................................... 457 Douglas W. Bousfield, Jong-Suk Sonn

SESSION 15: CARBON MANAGEMENT II The Forest Products Industry at an Energy/Climate Crossroads ................................................................................. 499 Marilyn Brown

The Role of Innovation and New Technologies in Control of GHG Emissions ............................................................ 500 Ron Brown

SESSION 17: OXIDIZING BIOCIDES FOR PAPERMAKING Monochloramine Chemistry for Biological Control ....................................................................................................... 501 M. Tod Stoner, Janet H. Woodward

All Oxidizers are Not Equal Performers.......................................................................................................................... 535 Russell J. Jerusik, Chris K. Davis

Minimizing Corrosion Concerns with Oxidizing Biocides by a Targeted Biofilm Control Approach ....................... 566 Ken Keegan, Mark Nelson, Juhana Ahola, Marko Kolari

A New Dual Biocide Concept for Fine Papermaking...................................................................................................... 598 Jani Kiuru, Jenni Sievanen, Irina Tsitko, Heikki Pajari, Pauliina Tukiainen

SESSION 18: CURRENT & FUTURE PAPER AND TISSUE MACHINE INNOVATIONS Evolution of OptiConcept – Entering a New Era............................................................................................................ 630 Frank Swietlik, Henri Vaittinen, Teppo Kojo, Sami Anttilainen

Overview of Modern Tissue Machine Technology.......................................................................................................... 657 Brian Christiansen

Harnessing Disruptive Technologies - Routes for Innovative Paper Products............................................................. 694 Graham Moore

SESSION 19: PAPER MACHINE PERFORMANCE MONITORING Tips and Tricks with Using IR Cameras in Paper Mills................................................................................................. 752 Robin J. Thon

New Method to Compare CD Profile Measurements with Process Measurements ..................................................... 771 Yurij Duda, Mika Suojarvi, Jarmo Kahala

Analyzing 2-Dimensional Variation based on Scanning and Imaging Measurements................................................. 796 Markku Ohenoja, Johanna Ylisaari, Kauko Leiviska, Risto Ritala

Improved Decision Support with Structured Process Historians .................................................................................. 826 Kimmo Konkarikoski, Risto Ritala, Olli Saarela, Ismo Penttinen

SESSION 20: COATING BEST PAPERS Nanofibrillated Cellulose with Fine Clay as a Coating Agent to Improve Print Quality............................................. 854 Hitomi Hamada , Jacqueline Beckvermit, Douglas W. Bousfield

The Influence of Kaolin Aspect Ratio on Offset Printability ......................................................................................... 881 Chris Nutbeem, Janet Preston, Anthony Hiorns, John Husband

VOLUME 2 Innovative Approaches Improve Competitiveness in an Industry Full of Challenges ................................................. 922 Stig Renvall, Jin-Doo Kim, Pekka Salminen

SESSION 22: PIMA INNOVATION I The Reliability Revolution: How Implementing Reliability Basics Can Transform Your Plant ................................ 957 Magnus Pousette

Gaining the Competitive Edge - Improving Business Operational Agility and Performance ..................................... 958 Ken Starek

SESSION 23: NOVEL FUNCTIONAL ADDITIVES Foam Control on Closed Water Loops and High Temperature Paper Machines ........................................................ 978 Robert Wilson, David Previs

Synthesis of Sizing Agent with Tapioca Starch and Fluorinated Acrylate Monomer.................................................. 999 Hongxiang Zhu, Hak Lae Lee, Guodong Yin, Hainon Song, Shuanfei Wang

High Performance Low Shear Alkenyl Succinic Anhydride Sizing............................................................................. 1030 Juha Lindfors, Reetta Strengell, Alexander Wahl

Bulk Enhancement by Functional Chemical Treatment .............................................................................................. 1051 Clayton J. Campbell, Michael P. O'Toole

SESSION 24: INNOVATIONS IN PAPER MACHINE CLOTHING – PANEL DISCUSSION Paper Machine Clothing Trends in Today's North American Market ....................................................................... 1075 Bill Luciano

Paper Machine Clothing Innovation Panel.................................................................................................................... 1092 Keith Kemp

SESSION 25: PAPER MACHINE ENERGY OPTIMIZATION THROUGH PC TECHNOLOGY Minimization of Paper Machine Drying Costs Through the Use of Advanced Process Controls ............................. 1103 Dean Ferguson, Marty Roberts

Energy Savings in Paper Machine Vacuum System - How to Utilize Modern Process and Variable Speed Drive Technology.................................................................................................................................................. 1129 Jussi Lahtinen, Juha Karvinen

Energy Savings by Process Optimization – Reducing Vacuum Demand in the Paper Machine............................... 1164 Carl Hakansson

SESSION 26: INK JET MATERIALS Polyvinyl Alcohol in Ink-Jet Coatings............................................................................................................................ 1192 Ken Kumaki, Shinsuke Nii

Silica Pigments for use in Commercial Color Inkjet, High-Volume, On-Demand Printing Systems ....................... 1220 Demetrius Michos, W. R. Grace

High Solids Modified Calcium Carbonates- A Concept for Ink-Jet Papers ............................................................... 1221 Dan Varney, Vesa Kukkamo

Using Kaolin to Tune Key Performance Parameters in Future Publication Ink Jet Grades .................................... 1248 Ching Chen

SESSION 27: COATER RUNNABILITY & CALENDERING The Mechanics of Web Release from a Roll During Size Press Operation ................................................................. 1249 Douglas W. Bousfield, Rajan Iyer

Optimizing Solids and Rheology in Blade Coating Using Pigment Blends ................................................................. 1282 Guillermo Bluvol, Michael Kassberger, Franz Reichart, Bruce Nelson

Metal Belt Calendering of Uncoated and Coated Paper............................................................................................... 1330 Henri Vaittinen, Minna Korkeamaki, Petri Ristola, Maiju Aikala

Optimization of Board Calendering Based on Analytical Methods............................................................................. 1374 Eduard Davydenko, Walter Gnilke, Mark A. Sorenson

SESSION 29: CARBON MANAGEMENT III Print vs. Digital Media: False Dilemmas and Forced Choices ..................................................................................... 1418 Don Carli

Carbon Management Uncertainty.................................................................................................................................. 1419 Ben Thorp

SESSION 31: SHOE PRESS INNOVATIONS – PANEL DISCUSSION Recent Shoe Press Developments ................................................................................................................................... 1420 Thomas R. Kast

Paperchine Shoe Design Innovations ............................................................................................................................. 1436 Jim Anema

Modern Closed Draw Pressing ....................................................................................................................................... 1448 Frank Swietlik

SESSION 32: FIBER SUSPENSION FLOWS 1 Two-Sided Drainage Handsheet Machine ..................................................................................................................... 1468 Alois Vanerek, Jimmy Jong, Young-Il Jeong, Francoise Forel, Jose-Antonio Orccotoma

Development of Initial Dewatering at Shoe and Blade Gap Former ........................................................................... 1499 Ari Puurtinen, Juha Salmelo, Pasi Selenius, Antti Koponen

SESSION 34: MULTI-LAYER COATINGS Considerations for the Selection of Binder in Double and Triple Coated Systems - Effect of Under Layer Starch Migration on End Use Performance ....................................................................................................... 1521 Greg Welsch, Francis Dobler, Monika Plass, Marianne McKelvy, Dominique Poncelet, Jean Marbaix

Precoat and Topcoat Effects on Final Printability - Different Precoat Pigments (100% Parts) ............................... 1583 Daniel Matte, Patrice Mangin, Robert Lanouette, Claude Daneault

Metered Size Press Coating – What to Expect from Specialty Starches? ................................................................... 1659 Detlev Glittenberg

SESSION 35: NEW TECHNOLOGY SHOWCASE (COATING) Reduce Costs with High Solids Coatings ....................................................................................................................... 1710 Mike Strutz

Laboratory Tester for Curtain Coating......................................................................................................................... 1726 Martin Kustermannn

Gas-fired Infrared Replacement Solution ..................................................................................................................... 1735 Gerald J. Lucidi

Lab Permi – Portable Porosity Analyzer ....................................................................................................................... 1759 Randy Southin

SESSION 36: PIMA INNOVATION II Entrepreneurial Approach to Paper Industry Innovations.......................................................................................... 1771 Pekka Komulainen, Heikki Mustalahti

Rethinking the Place of Patents in the Innovation Process - A New Model for Improving Innovation ROI ................................................................................................................................................................................... 1796 Jackie Hutter

VOLUME 3 SESSION 38: NEW TECHNOLOGIES FOR STRENGTH IMPROVEMENT Meeting New Sustainability Requirements in Packaging Through Application of Novel Chemistry....................... 1815 Jonathan M. McKay, Jack Block

New Dry Strength Technology for Weight Reduction in Packaging Grades.............................................................. 1837 Matthew Wright

Next Generation Increased Solids Dry Strength Additive............................................................................................ 1867 Rosy Covarrubias, Daniel Glover

SESSION 39: PRESS SECTION INNOVATIONS Improving Sheet Quality: Rolls and Press Felts Working Together ........................................................................... 1898 Arthur Bullerwell, Ronald Goglick, Glen Harvey, Michael McGuffey, Eric Gustafson, Bill Butterfield, Robert Olinger, Robert Moore

Improving Shoe Press Performance through Design, Materials and Operations ...................................................... 1915 David Burton

Press Fabric Technology for the New Millennium........................................................................................................ 1963 Daniel Hédou

SESSION 40: INNOVATIVE MEASUREMENT & CONTROL APPLICATIONS FOR PAPERMAKING Continuous In-Line Fiber Quality Measurement and Prediction of Sheet Quality Potential ................................... 1975 Ola Johansson, Hakan Karlsson

Surface Fiber Orientation Measurement from On-line Imaging................................................................................. 2003 Ross Machattie, Antti Paavola, John Shakespeare

SESSION 41: BARRIER COATINGS Metallized C1S Paper with Moisture Barrier: The Ultimate in Sustainability .......................................................... 2024 Randy Field

Making the Most of the New Breed of Fluorochemical Treatments for Paper........................................................... 2048 Mike Sanchez

SESSION 42: COATER ON-LINE INSPECTION & MEASUREMENT Comparison Between a Curved Soft Tip Metering Element and a Conventional Blade in Coating of Paperboard....................................................................................................................................................................... 2099 Lars Järnström, Luciano Beghello, Per Emilsson

A Review of Camera Based Surface Inspection Technologies for Pulp and Paper .................................................... 2140 Brian Mock

A New Method for Evaluating the Surface Abrasivity of Paper.................................................................................. 2172 Nina Deng, Sylvie Ghanime, Steve Smallwood, Jean Hamel, Xuejun Zou, Son-Ha Luu

SESSION 45: FILLER IDEAS AND DEVELOPMENT A Surface-Modified Talc for Reduced Linting Propensity........................................................................................... 2209 Vicente Lasmarias

Study of Use of Beneficiated Pulverized Coal Fly-Ash as Filler and Rice Straw Fibers in Manufacturing of Paper.................................................................................................................................................. 2237 Akhouri Sanjay Kumar Sinha, Manohar Singh, Surendra Pal Singh

Unique Fixative Technology Improves Particle Fixation ............................................................................................. 2295 Loren B. Stenfors

SESSION 46: FIBER SUSPENSION FLOWS 2 Modeling the Fibre Anisotropy Profile in Shear Layers Leaving a Planar Contraction ........................................... 2320 Marko Hyensjö, Anders Dahlkild, Tomas Vikstrom

Drainage Pressure Oscillations During Roll Forming .................................................................................................. 2358 Claes Holmqvist, Daniel Soderberg

Predict the Drainage Characteristics of Forming Fabrics on a Paper Machine......................................................... 2390 John Xu, Roger Danby, Dale Johnson, John Vanderkolk, Alan Cheverton

On Suction Box Dewatering Mechanisms...................................................................................................................... 2418 Peter Aslund, Hannes Vomhoff

SESSION 49: INNOVATIONS FOR TISSUE MAKING Measuring Roll Alignment as a Means of Preventive Maintenance in Tissue Converting ........................................ 2458 Philip McCarthy

Application of Polyurethane Roll Covers for Yankee Pressure Rolls ......................................................................... 2492 Charles Hunter, Gary Kilbourne, Franz Danzler, Bill Butterfield

DIP Process Innovation and Cost Reduction in Tissue Mills ....................................................................................... 2531 Marco Pescantin

From Stock Preparation to the Finished Product – An Integrated Approach to Develop Cost-effective Solutions in Tissue ........................................................................................................................................................... 2572 Jeff Peters, Mike Paczkowski, Mike Molter

SESSION 50: INNOVATIONS IN OFF-LINE PAPER TESTING Prediction of Fold Cracking Propensity through Physical Testing ............................................................................. 2605 Roman E. Popil

Measurement of Small-Scale Permeance Variation...................................................................................................... 2627 Hannes Vomhoff, Mikail Bouveng

A New Instrument for Measurement of Out-of-Plane Dimensional Stability of Paperboard ................................... 2665 Marco F. C. Lucisano, Hannes Vornhoff

A New Model for Converting Short Span Compression with Other Measurements to Ring Crush ........................ 2697 Roman E. Popil

VOLUME 4 SESSION 51: HEADBOX AND FORMING INNOVATIONS FOR PACKAGING GRADES Advancements in Gap Forming for Lighter Weight Board and Packaging Papers................................................... 2722 Thomas R. Kast

New Compact Concept for Two-Ply Lightweight Containerboard Grades ................................................................ 2764 Hannu Turpeinen, Kari Raisanen, Hannu Partanen, Teuvo Virkkunen

Upgrading Headbox Technology to Improve Quality and Increase Strength on Board Grades .............................. 2807 P. Gelinas, D. D'Eea, M. Foulger

A Simplified Headbox for Primary or Secondary Applications - YBR ....................................................................... 2835 James L. Ewald, Greg Welcher

SESSION 52: NEW DEVELOPMENTS IN THE FUTURE OF PAPERS Paper – The End of the Road, or Dawn of a New Era .................................................................................................. 2881 Graham O'Neill, Janet Preston, John Charnock

SESSION 53: COATING SAFETY Coating Machine Safety Practices and Controls – A Pilot Coater View ..................................................................... 2912 Greg Welsch

Incident Investigation - Application of Root Cause Failure Analysis.......................................................................... 2913 Greg Bates

SESSION 55: TISSUE ADDITIVES Predicting the Performance of Creping Adhesives ....................................................................................................... 2914 Doeung Choi, Timothy Patterson

Using Enzymes to Improve Tissue Manufacturing ....................................................................................................... 2946 David Jones, Jonathan Morissette, Vincent Roy

An Innovation Journey in Tissue Making – A Fractionation System for Controlling Ash and Fines in Whitewater....................................................................................................................................................................... 2980 Joe McDonald, Don Guay, Jeff Lindsay

SESSION 56: NEW PAPERMAKING PROCESS INNOVATIONS Advancements in Stock Preparation and Approach Flow Systems............................................................................. 3002 Jon Kerr

Evaluation of Multiport Cylindrical Dryer ................................................................................................................... 3028 Jerry Timm, Greg Wedel, David M. France

Calender Residual Barring Correction During Roll Grinding .................................................................................... 3058 Frédéric Parent, Jean Hamel

SESSION 57: HEADBOX/FORMING INNOVATIONS FOR PAPER GRADES – PANEL DISCUSSION Paper Properties of Interest to Printers of White Paper Grades................................................................................. 3096 Michael Bilodeau

PCR StableFLO, the next generation of flow Uniformity ............................................................................................ 3107 James Ewald, Greg Welcher

Forming Technology for White Papers.......................................................................................................................... 3134 Frank Swietlik

Press Configurations for White Paper Grades.............................................................................................................. 3163 James Anema

SESSION 58: FLEXOGRAPHIC PRINTABILITY Effects of Coat Weight and Pigment Selection on Flexographic Printability of Coated Test Liners........................ 3171 Sinan Sonmez, Paul D. Fleming, Margaret K. Joyce, Oznur Ozden

Influence of Ink Chemistry and Uncoated Paper Surface Energy on Setting and Transfer of WaterBased Flexographic Inks ................................................................................................................................................. 3212 Wing T. Luu, Douglas W. Bousfield, John Kettle

The Photocatalytic Paper With Coating Formulations of Titanium Dioxide and Natural Zeolite ........................... 3254 Qi Li, Kelsey Lynne Dykstra, Paul D. Fleming III, Margaret K. Joyce, Dewei Qi, Puina Ari-Gur

SESSION 60: ALTERNATIVES TO GAMMA RADIATION FOR WET END ANALYSIS – PANEL DISCUSSION Alternatives to Gamma Radiation for Wet End Analysis ............................................................................................ 3264 Tom Rodencal

L&W Consistency Meter................................................................................................................................................. 3275 Lars Kange

Alternatives to Gamma Radiation for Wet End Analysis ............................................................................................ 3295 John Neun, Dennis Hill

FiberScanONE Portable Microwave Consistency Meter Based on Planar Microwave Sensor ................................ 3307 Luca Canali

ConsistencyCheck Portable Measuring Device ............................................................................................................. 3322 Kari Luostarinen

SESSION 61: ADVANCED UTILIZATION OF IMAGING TECHNOLOGY New Method of Monitoring Paper Machine Dynamics with Video ............................................................................. 3328 Les Frackowiak

Web-Wide Diagnostics of Paper Properties Based on Fault Detector System Images............................................... 3364 Jukka-Pekka Raunio, Ville Tirronen, Risto Ritala, Isto Nironen, Tuomo Rossi, Tommi Karkkainen

SESSION 62: YOUNG PROFESSIONALS – COATING 101 Coated Paper and Paperboard Overview ...................................................................................................................... 3386 Charles Klass

Introduction to Coated Paper - pigments, binders and additives ................................................................................ 3430 Steven Ottone

Introduction to Printing Technology.............................................................................................................................. 3493 David Smith

SESSION 64: FLUID MECHANICS OF DRAINAGE & DEWATERING Engineered Forming Fabric Drainage Channel - Is There a New Forming Fabric Revolution Coming? ............... 3543 Oliver Baumann

Effect of Initial Dewatering Lay-Out of a Gap Former on Sheet Structure and Printability ................................... 3563 Ari Puurtinen, Jukka Muhonen

Improvement of the Drainbility of Poplar APMP Pulp by Enzymes Treatment ....................................................... 3588 Wu Qin, Chen Jiachuan, Yang Guihua, Wang Shuangfei, Kong Fangong, Dong Yi Author Index