Case Study: Folding Box Board Outer Ply MFC Trial Results

MFC Grinder Case Study: Folding Box Board Outer Ply

Filler increase, chemical pulp reduction, and improved coating hold-out

Background

This trial focused on a coated Folding Box Board (FBB) grade where adjustments were made to optimise material usage and performance.

  • Outer layer filler content was increased
  • Grammage was shifted from outer layers to the middle layer
  • MFC was produced using a G250 grinder with eucalyptus pulp

Trial Results

The trial demonstrated that redistributing material layers and introducing MFC can significantly improve efficiency without compromising quality. Key structural changes included:

  • Reduction of outer layer grammage
  • Increase in middle layer grammage
  • Optimised fibre and filler balance
Case Study: Folding Box Board Outer Ply MFC Trial Results
Case Study: Folding Box Board Outer Ply MFC Trial Results

Trial Outcomes

  • 2% MFC and +10% filler added to both outer layers
  • Outer layer grammage reduced by 8.5 g/m² (each layer)
  • Middle layer grammage increased by 17 g/m²
  • 34% reduction in chemical pulp usage
  • Maintained specification and process performance
  • 50% reduction in ply bond starch usage
  • Reduced coating inputs: 1 pph latex pre-coat reduction
  • 2 g/m² coat weight reduction
  • Estimated cost savings: 20–35 EUR per tonne

Key Takeaway

This trial shows that combining MFC with strategic layer optimisation can significantly reduce raw material costs while maintaining product performance.

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