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PAPER Matters! was the first general paper conference in theUK for nearly a decade. This sell-out event was held in the confer-ence room at UPM Shotton, and featured an international audiencecovering Austria, Belgium, Germany, Poland, and The Netherlandsas well as the large contingent from the UK. Indeed, the speed withwhich tickets were sold and the auditorium filled is testament tothe appetite for such an event, which is hardly surprising given thestature of the speakers gathered together in one place. Rest assured,PITA will be looking to repeat the event, possibly on a biannualbasis; in the meantime, a summary of the various papers can befound below and in subsequent pages of the journal.

Introduction to UPM Shotton - Dave Ingham / UPM ShottonUPM is a major Finnish company operating six major busi-

nesses: UPM Biorefining; UPM Energy; UPM Raflatac (labels);UPM Paper Asia; UPM Paper ENA; and UPM Plywood, all ofwhich are assimilated under the Biofore strategy, which inte-grates efficient use of renewable materials and energy; produc-tion of renewable and recyclable products; and innovations andnew businesses (for example UPM Biorefining in Lappeenranta,and the new UPM Biocomposites business unit); and was de-vised to enable the company to manage and adapt to a changingworld and marketplace.

Although last year saw the closure of PM1, the company isstill investing in the Welsh site; in May 2016 it started to con-sume solar energy from the nearby solar farm (see NEWS formore information) and they are in the process of installing a lowpressure steam turbine to take excess steam not now requiredfollowing the closure of PM1, in order to produce more electric-ity from their biomass power generation unit.

‘Transformation’ - Berry Wiersum / CEO Sappi EuropeWe were delighted to have Berry Weirsum, a very dis-

tinguished, well-known and much-respected senior mem-ber of the European paper industry, give the keynoteaddress on the subject of Transformation – a wide-rang-ing overview about how manufacturing can survive in anevery changing world.

To introduce the subject, Berry spoke about currencyfluctuations, variation in the price of oil, GDP growth,unemployment, ageing and demographics, before reach-ing the topic of digitalisation. As we all know, the digital

age has presented major problems to some parts of the paper in-dustry. Analysts predict that, going forwards, these will continueto decline by around 1% per annum as the younger generationgrows and matures in a predominantly digital age.

Looking at digital in more detail, there is now a generalchange from people buying new appliances for the sake of up-grading, to buying new appliances due solely to functionality –and the big new growth area of functionality is health. This in-creased emphasis on health also has benefits for the paper indus-try, with the rise in hygiene product use worldwide.

The topic of ‘disruptive technology’ introduced the case ofaluminium: a material discovered in the 1820s, used for makingexpensive jewellery three decade later, but which had to waituntil the advent of airplanes before it finally ‘took off’. Likewisetoday, new materials are being produced at ever increasing rates,and many just await that ‘eureka’ moment to be transformed intoproducts of the future (some of which are touched upon by Gra-ham Moore later).

As regards Industry 4.0, the paper industry is advantaged dueto the number of sensors on most modern paper machines. Thismakes it relatively easy to introduce and take advantage of (seethe article by Peter Fisera and Roman Klug for an example).

In conclusion, the world is transforming quickly. New devicehype is giving way to useful functions; Government and politicscontinue to lag behind events as prevailing geo-political systemsdisintegrate; and industry is reinvented with the birth of ad-vanced manufacturing. Despite everything, our industry has agreat, but challenging, opportunity - we are witnessing the endof an era and the start of a second Renaissance!

The Role of Paperboard in the Future of the Packaging In-dustry - Gabriel Sousa / Pöyry Management Consulting

This presentation was based upon two recent reports compiledby Pöyry: Packaging Drivers, from now to 2025 (prepared onbehalf of The Stationers, UK), and World Paper Markets up to2030. After showing a simple timeline (Figure 1) which includedsome of the major developments introduced during the last cen-tury, all of which have contributed to the modern packaging in-dustry we know today, Mr Sousa focussed mainly on thepaper-based sector.

Currently paperboard makes up around 31% of the packagingmarket by material, its closest rivals being rigid plastics at 24%and flexibles at 18%. Although the public tends to denigrate‘packaging’ as a subject, there is no doubt it is of fundamentalbenefit to both producers and consumers, and as such growth inall regions and of all substrates is forecast, but the rate of growthvaries. In the case of paperboard, volumes are forecast to in-

PAPER TECHNOLOGY AUTUMN 2016 NEW INSIGHTS ON APPLICATION OF HIGH-YIELD PULP

PAPER Matters! Conference Review

Figure 1. Timeline showing introduction of various packaging materials.

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crease over the next decade, although its total market share isdue to decline slightly in favour of both rigid plastics and flexiblefilms.

Concentrating solely on paper substrates, currently the sectoris dominated by containerboard, which makes up 69% of the total(segregated as 49% recycled and 20% virgin). Below that comesWLC (10%), FBB (4%) and a host of other minor grades. Unsur-prisingly, containerboard is expected to grow further by around2%pa; this is less than tissue, which is forecast to show annualgrowth of 3%, but well ahead of carton board and sack papers.

Finally, due to M&A activity during the 2000s, the industryconcentration level grew, particularly in Japan, North Americaand China, but in Western Europe there is still further consoli-dation possible in the area of containerboard.

Speciality Papers – Future Issues & Trends - Dr GrahamMoore / PITA

Dr Moore has advised speciality papermakers worldwide, andused this presentation to crystallise his advice into some key cri-teria, which he outlined with examples to show their application.

� Innovation. The speciality paper sector continually hasto evolve to meet manufacturing challenges and the de-mands and unmet needs of the market place. (e.g. FreeForm Pack, Alpha Free, and Powercoat).

� Material Science. Developments in material science havebeen reflected in an expanding range of raw materials thatcan be used in conjunction with wood fibres to provideadditional functionality in speciality paper products. (e.g.:Durapulp, Kelheim viscose fibres, and Barrisurf).

� Thinking ‘outside the box’. The creation of new paper-based products often results from personnel not directlyinvolved in the paper sector. To maximise the potentialreturns from such products, the paper industry needs toconsider how it can harness and exploit creative and in-novative inputs. (See the sustainable expanding bowl andthe Gogol Mogol egg package).

� R&D capability. In order to develop and exploit innova-tive products, access to R&D resource (internal or exter-nal) is key. With many innovative ideas coming fromoutside the paper industry, the challenge remains how tobe involved earlier in the innovation process and developthe necessary links with appropriate groups.

� Supply Chain. Not directly applicable to the specialitysector, where there are established links with both con-verters and often the ultimate end user; however, an im-portant consideration for those companies consideringentering the speciality paper sector.

� Re-invention. Product development has to be continuousto ensure products meet ever demanding needs of a di-verse customer base. The role of third party technologyproviders will increase to enable paper products to evolveand compete more effectively with alternative materialsand substrates. (e.g. EarthCoating mineral coating; Mem-ori security card).

� Third party supplier. Re-inventing a traditional indus-trial concern such as a paper company is not an easy task,yet there are successful examples (e.g Mohawk and Ap-pvion).

� 3D capability. Traditionally, paper has only been used tomanufacture packages with flat surfaces. This restrictionis being eroded and opening up opportunities to develop3D paper products. (See FibreForm; and current workproject at Innventia).

� ‘Last Man Standing’. Demand for a number of productsand grades has declined with changes in technology, mar-ket shifts, etc. However, often there is ‘rump’ of demandthat can be served effectively by smaller, speciality mills.(e.g. carbonless copy paper; diazo paper).

Finally, looking forward, significant new growth opportuni-ties for speciality papers will develop over the next decade.Major growth drivers will include: water-based barrier coatings;enhanced papers (latex, resins, synthetic fibres); paper vs plastic;and inkjet printing.

Experiences with Agro Fibres, from pilot towards full-scaleproduction - Leon Joore / Millvision

Dr Joore described the work undertaken by a small group ofbio-based academic institutes and application centres in TheNetherlands, grouped under the heading Biobased Infrastruc-ture for Knowledge (BIK). Together these centres investigateuse of agricultural materials, which include grass, flax, hemp,water plants and greenhouse residues.

Starting in around 2007, following a shortage of recoveredpaper, Millvision B.V. examined the use of natural grass as asubstitute for mechanical fibre in box-making. After a numberof iterations the project resulted in production of around100,000 boxes made with grass as a component. The grass was‘biopulped’ in a similar way to flax, with bacteria used to breakdown the fibre structure and release protein; membrane filtra-tion then removed the protein fraction, which was sold as a by-product – an excellent example of a small-scale biorefinery inaction. Although the initial project was dropped due to eco-nomic considerations, paperboard manufacturers are lookingagain at this raw material, and only last year one firm made 80tonnes with grass as a 10% furnish substituent in testliner.Meanwhile, Huhtamaki has gone a stage further and taken itto full commercialisation, using grass as a constituent of ‘green’egg boxes.

Greenhouses play a large part in the agricultural industry ofthe Netherlands, and so interest has been shown in a number oftheir agro-residues, mainly for inclusion in low-grade productssuch as greyboard. Work using paprika stems has shown excel-lent results, with the added benefit that, compared to use of re-covered fibre, these residues show no migration issues whenused in food packaging.

Other work currently underway involves use of cocoa beanhusk in packaging; myscanthus in toilet and office grades; onionin packaging; and both hemp and sorgrum for various grades. Inaddition they are assessing the use of these different raw mate-rials as sources of cellulose oligomers and of nanocellulose. Inconclusion, all focus is on practical (rather than theoretical) ap-plication of science to using these somewhat unusual fibrous rawmaterials as precursors of a circular bio-economy – and a majorbonus for this work to take place has been the availability of apilot paper machine!

Improving strength properties with recycled fibre furnishesusing nanocellulose preparations - Nigel Jopson / on behalfof Brunel University

‘Nano’-cellulose describes particles of around 5-20nm inwidth, with length in microns, and of varying morphology. Theobjective of this study was to take nanocellulose obtained locallyin the UK from hemp, and to investigate if it can be used to im-prove the properties of paper made from recycled fibre. Thework followed two strands: first to identify the most effectivetreatments by furnish; and second, to see how tolerant nanocel-lulose treatment is to various process additives.

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Each of three furnishes (OCC, ONP and office waste) weredispersed at 4% consistency, without use of caustic soda or wet-ting agents. Nano-treatments were used at 2.5% on fibre, drybasis. The furnish containing the nanocellulose was dispersedusing a modified sheet forming method developed by Raj Gill(Figure 2), at 0.5% consistency, then the sheets were couched,pressed and dried using standard methods. The initial screeningtests found the strength properties of office waste were improvedmost – up to 26% tensile, 41% stretch and 110% TEA. ONP andOCC furnishes showed significant increases in tensile (17% and11% respectively) but no change in TEA or stretch.

The second part of the experiment focussed solely on OCC,since this has the greatest need for strength improvement, giventhe low quality of current recovered fibre. This part assessed theeffect of PAM retention aid, AKD sizing agent and Calopakecarbonate filler. In all cases, nanocellulose was added after allother additives, and just before sheet formation. Unsurprisingly,results showed some variability, however: filler addition causeduniversal loss of strength; sizing addition generally showed littleeffect; while using retention aid increased strength-related prop-erties.

It was concluded from these small-scale laboratory trials thatnanocellulose has the ability to improve both extensive and com-pressive strength properties of paper made from recycled fur-nishes. Furthermore, the individual furnishes and thenanocellulose samples can be ‘tuned’, with formulations requir-ing some rebalancing. Therefore it is justified to look at progress-ing to pilot scale work.

Supplier Showcase Slot – Salvtech & IBSSalvtech is a Welsh company, operating in the fields of pulp

and paper, waste and recycling, that offers project managementand research and development services to its clients. It is also an

agent for a number of different companies, one of which gavethe main presentation on the day: IBS Paper PerformanceGroup of Austria.

This supplier highlighted the iTable TMconcept, which is usedin over 70 sites worldwide. It consists of a fully adjustable Four-drinier sheet forming zone, which is achieved by having a seriesof foils mounted so each can be adjusted for height and angle.This allows infinite adjustment of these parameters for precisecontrol of drainage and stock activity at any machine speed orbasis weight. The ability to alter and optimise drainage, forma-tion, basis weight and moisture profile, and fibre orientation,gives the papermaker possibilities to improve efficiency and ex-perience economic benefits.

Also presented was the safetyMASTER, a traversing meas-urement device for doing moisture and permeability profiles inthe press section without crossing the paper machine. It consistsof a stainless steel beam and a shuttle which can carry any of thestandard available measurement devices. The shuttle is fully au-

PAPER TECHNOLOGY AUTUMN 2016 PAPER MATTERS! CONFERENCE REVIEW

Figure 2. Modified sheet former developed by Raj Gill.

AutomationX is an internationally operating techno-logy company, which is specialised in automation solutions for pulp and paper industry. Base for these solutions are our own soft- and hardware products.

Controlling

Visualizing

Reporting

Production management (MES)

Energy management

Process Optimizing (MPC)

Modular - Scalable - Universal

AutomationX GmbHLauzilgasse 13

8020 GrazTel. +43 (316) 2704-700Fax +43 (316) 2704-708 www.automationX.com

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tonomous, with no connections to power, air or water being nec-essary. Benefits for the papermaker include: safety; reproducibil-ity of measurements; and the ability to measure in difficult toaccess zones.

Energy & the Environment – Future Challenges &Opportunities for Papermaking - Steve Freeman & DebbieStringer / CPI

This presentation focussed on resource planning to 2050; assuch it coincides with work undertaken by DECC/BIS (nowBEIS) in the UK, and by CEPI in mainland Europe. The reasonfor choosing this seemingly long time period is that, for highcapital intensive industries such as paper, this encompasses a sin-gle investment period; the endpoint is also far enough away forcompetitive issues not to inhibit strategic thinking.

Taking energy first, UK Government policy is to lead globaldecarbonisation, and there is no indication this long-held stanceis likely to change. With that in mind, CPI and PITA have beenworking with consultants and DECC/BIS to establish a roadmappulp and paper manufacturers can adopt to decarbonise goingforward. This work is still ongoing (the next meeting is plannedfor 20 October in Stockport) and all are invited to participate.

In terms of raw materials, traditional users of forest fibre al-ready feel under pressure, due in no small part to the use of thismaterial for energy production. Indeed, while this material is sig-nificantly more expensive than coal, Government subsidy com-pletely alters the economics and skews the market in favour ofburning reusable raw materials. In future, more pressure on‘waste wood’ and possibly on recovered paper as feedstock forenergy production can be anticipated.

Air emissions are mostly linked to energy generation. The UKis an independent signatory to the Gothenburg Protocol, thiscommitment is enshrined in legislation, and the emission ceilingsfor S, NOx, VOC’s & NH4 are only going to get tougher in yearsto come.

Water use and water scarcity is another item that is expectedto impact the industry in coming years, as there is need for Gov-ernment to see that water resources are managed to ensure re-silience as we try to adapt to climate change. Key to this isAbstraction Reform planned for England and Wales (there areno similar plans in Scotland). Plans are to implement the reformspost 2020, and by definition they will impact in particular thosemills sited in water stressed areas.

To summarise, for the UK paper industry to thrive in the com-ing decades there are a number of significant areas it will needto be aware of, all of which are impacted by UK Governmentpolicy, much of which has yet to be formulated.

Classical MPC powered by Physical Simulation is the Wayinto the Industry 4.0 - Peter Fisera / CF Procsim GmbH

A full rendition of this paper is printed elsewhere in this edi-tion (pages 20-23).

Improving Quality, Safety, Reliability and Efficiency withHoneywell’s QCS System - Barry Corcoran / Honeywell

Traditional scanner systems are based around rigid machineframes, carry separate power and signal cables along with waterand air supply lines, and have numerous motors, belts and pul-leys. By contrast, the new Honeywell innovation described inthis presentation does away with many of these requirements andinvolves a cut-down system based upon tensioned steel wires.

The ZipLine system is currently available for plastic webmanufacturers and nonwoven lines; a tissue version is imminent,after which one for smaller paper machines (up to around 4mwidth) will be launched. It does away with the scanner and

tracks, and instead the sensor head is mounted on the tensionedcables. The result is 90% fewer parts than are required for a tra-ditional set-up, resulting in a system that ships in a box ratherthan a dedicated HGV and that can be installed in a matter ofhours. The sensor can house a radiation source for weight meas-urements, IR detector for moisture, and a tissue crepe head (seePaper Technology, Spring 2016, pp.9-15).

The sensor head is positioned between two cables: one pro-vides support and the other power, and since they are of differentcross-sectional diameter this rules out problems caused by har-monic vibration. Furthermore, the cable tension is set so that sagin the middle is a maximum of 1mm, which has no appreciableimpact on measurement accuracy. The weight and moisture sen-sor works on substrates up to 150gsm and 30% moisture.

Benefits claimed include simpler operation and lower generalmaintenance since there are no expensive power tracks to re-place; heads are permanently self-aligned meaning there are nodrive belts that have to be adjusted; no carriage wheels that willwear out and have to be replaced; no Air or Water supplies to ad-just; and with 90% fewer parts it reduces both spare parts inven-tory and the potential for part failures. Overall Honeywell seethis as a low cost of ownership product for those with machineswhere this system will prove suitable.

Supplier Showcase – ABB/L&W OptiTopoA short rendition of this presentation has been supplied by the

company and is printed elsewhere in this edition (page 30).

Who Is Going to Optimise Paper Machine Clothing? -Marcel Lensvelt / Feltest

A full rendition of this paper is printed elsewhere in this edi-tion (pages 44-46). Please note, we would welcome correspon-dence from any readers relating to Marcel’s proposal.

Application of flow cytometry in Papermaking - MarcusPhilpott / Axchem

A full rendition of this paper is printed elsewhere in this edi-tion (pages 16-20).

Magnesium Based Process Promoters designed forDeinking Applications - Bartek Stawicki / BIM Kemi

Deinking processes tend to be run in an alkaline environment,for a number of reasons: fibres swell in alkali, which aids inkdetachment; alkali is needed for activation of peroxide bleach;and fatty acid based ink collectors are alkaline by reason ofsaponification. Typically, two chemicals will be used to producethe right conditions: caustic soda and sodium silicate. However,current technology based on sodium hydroxide and waterglassleads to some unwanted problems, which include: pulp darken-ing and brightness reversion; dewatering problems; ‘activation’of stickies and natural wood extractives; raised COD load; andscaling issues.

With that in mind, BIM investigated what could be done tocounteract some of these negative aspects of using alkali; re-search that led eventually to RemoBright, a surface-modifiedMagnesium Silicate Hydrate (MSH). Trials have shown this mul-tifunctional speciality chemical has many benefits, which in-clude: improved drainage; reduced energy consumption; lowerCOD; stickies are less problematic; operating costs are lower;and most importantly, optical properties are improved.

With the trends in the industry putting increasing pressure oncost reduction and process optimisation, magnesium-based spe-ciality chemistry for deinking processes offers some significantadvantages over the traditional sodium-based chemistry.

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