Microfibrillated Cellulose Outside of the Box

Per Svending, Johannes Kritzinger, Tania Selina and Jon Phipps, all FiberLean Technologies Ltd.

Presented by:
Per Svending
VP Marketing
FiberLean Technologies Ltd

Renewable and recyclable material for packaging!

Renewable & recyclable material for packaging

Global containerboard consumption growth

Global containerboard consumption growth

The corrugated box market is being transformed

corrugated box marketcorrugated box market

 

  • The primary function of corrugated boxes is to protect goods during transport.
  • The market is huge with some 160 Mton per year of linerboard and medium made worldwide.
  • Growth is broadly in line with GDP.
  • Demand for PRINTED boxes is growing significantly faster and will drive a transformation of the industry.

corrugated box market

Growing demand for printed white boxes

Growing demand for printed white boxesKey drivers:

  • Support product exposure
  • Regional, seasonal or target group adaption
  • E-commerce

Growing demand for “Point of Sale” displays

Growing demand for ”Point of Sale” displaysKey drivers:

  • Reducing man-hour cost for filling shop shelves
  • Support product exposure

Most high quality white boxes do not rely on White Top Liner as the print surface

boxes do not rely on White Top Liner

  • Post-Print is restricted to low/no impact print methods, i.e. Flexo and Inkjet, in order not to crush the medium.
  • Pre-Print offers higher quality but is more costly.
    • Labeling – A pre-printed paper or board is glued on top of the corrugated board.
    • Laminating – A pre-printed board or WTL is used as the top layer in the corrugated board.
  • Pre-Print also allows use of other high quality print methods, such as Offset and Rotogravure.

Current approaches to white corrugated boxes

Current approaches to white corrugated boxes

Digital printing destined to take over for packaging

  • Falling average print job volume.
  • Cost of digital print dropping with lower cost ink and growth in size and speed of printing presses.
  • The break-even point in cost is moving rapidly.

Digital printing destined to take over for packaging

Inkjet printing for packaging is evolving rapidly

Inkjet printing for packaging is evolving rapidly

 

 

  • Wider!
  • Faster!
  • Higher quality!
  • Pre-Print
  • Post-Print

The water challenge in printing

water challenge in printing

 

Offset
Water from Fountain solution only
4×100% CMYK => ~ 1-2 g/m2 of water ~1% moisture in 120 g/mlinerboard

Flexography
Water content of Ink is about 50%
4×100% CMYK => ~ 4-8 g/m2 water ~5% moisture in 120 g/mlinerboard

Inkjet
Water content of ink is about 90%
4×100% CMYK => ~ 16 g/m2 water ~13% moisture in 120 g/mlinerboard

Thinking outside the boxThinking outside of the box…

  • MFC is a strong and sustainable binder.
  • As a composite with mineral it can bring good light scattering to cover a dark base.
  • The MFC-mineral composite can be tailored to an ideal pore structure.
  • MFC-mineral composites are today commercially available in the kind of volumes needed for this application.
  • Actually, MFC-mineral composites would be an ideal ”coating” to make White Top Liner, if it could only be run on a coater.

MFC-mineral composite coating at the wet-end

MFC-mineral composite coating at the wet-end

 

  • Applied as a low solids slurry on to the consolidating base layer.
  • The composite of MFC and mineral has the ability to stay on the surface without penetrating into the base.
  • The top layer can be drained using existing foils and vacuum boxes.
  • Pressing and drying works as normal.
  • So far, the concept is proven only in pilot scale.

The composite structure prevents penetration into the base and makes wet-end coating possible

SEM pictures of a composite with 20% MFC from NBSK and 80% GCC at different magnifications.

SEM pictures of a composite with 20% MFC from NBSK and 80% GCCSuitable composites can be made in relevant scale, 10 kton/year to 100 kton/year, using similar on-site co-grinding plants as “FiberLean for filler increase” as practiced by Printing & Writing paper mills.

Generic mass balance, including water, on the wire

Generic mass balance

Increased press solids with the composite on top

similar couch solids

 

 

Similar couch solids

 

 

 

Press solids

 

 

+3% press solids

MFC-mineral composite coating at the wet-end

MFC-mineral composite coating at the wet-end

Pilot paper machine samples of FiberLean on Top on Kraftliner.
The different bases used in three trials visible on the right edge

The coating has interesting properties

  • High opacity for good optical coverage.
  • Good adhesion and Z-directional strength.
  • Excellent surface smoothness.
  • Very low permeability.
  • Microporous structure suitable for printing.
  • Ideal for making white boxes.

Thinking outside the box

Pilot scale results as a function of coat weight

Pilot scale results as a function of coat weightBase substrate:
86 g/m2 unbleached kraft linerboard.

White Top Linerboards

White Top Linerboards

White Top Liner made with MFC-mineral composite on top

Smooth and micro-porous surface

smooth and micro-porous surface (719 x 525)

  • Pilot trial run with wet-end coating made up of 20% MFC and 80% of a range of minerals
    • Minerals 1, 2, 3 and 4
    • Neutral and acid pH
    • Internal and surface sizing
  • WTL in reels for benchmark print test vs Commercial, high quality, WTL products.
    • Double coated White Top Testliner (CWTTL)
    • White Top Testliner (WTTL)
    • White Top Kraftliner (WTKL)

Flexography printing results

Smearing overview

Smearing overview

  • Sized MFC-mineral composite coatings compared to quality White Top Liner brands.
  • Smearing from 2*100% C+M wet-on-wet with printed web going through double rollers 0,3 seconds after print.

Smearing

Roll to roll aqueous Inkjet printing results

Roll to roll aqueous Inkjet printing resultsMFC-mineral composite on top is well above WTL in ink density.

Roll to roll aqueous Inkjet printing results

Bleeding overview

Bleeding overview

  • Sized MFC-mineral composite coatings compared to quality White Top Liner brands.
  • 33% extra drying had to be applied to CWTTL to avoid sticking.

Bleeding

Print properties as function of pore diameter of coating

Coated WTTL and MFC-mineral composite coated WTL

Coated WTTLMFC-mineral composite pore structure can be adjusted to optimum performance.

Renewable and recyclable material for PRINTED packaging, facilitated by Nanotechnology

Renewable & recyclable material