CA2503966A1 - Process for producing super high bulk, light weight coated papers - Google Patents
Process for producing super high bulk, light weight coated papers Download PDFInfo
- Publication number
- CA2503966A1 CA2503966A1 CA002503966A CA2503966A CA2503966A1 CA 2503966 A1 CA2503966 A1 CA 2503966A1 CA 002503966 A CA002503966 A CA 002503966A CA 2503966 A CA2503966 A CA 2503966A CA 2503966 A1 CA2503966 A1 CA 2503966A1
- Authority
- CA
- Canada
- Prior art keywords
- pigment
- weight
- kaolin
- web
- nip
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
Classifications
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H25/00—After-treatment of paper not provided for in groups D21H17/00 - D21H23/00
- D21H25/08—Rearranging applied substances, e.g. metering, smoothing; Removing excess material
- D21H25/12—Rearranging applied substances, e.g. metering, smoothing; Removing excess material with an essentially cylindrical body, e.g. roll or rod
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H19/00—Coated paper; Coating material
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H19/00—Coated paper; Coating material
- D21H19/36—Coatings with pigments
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H19/00—Coated paper; Coating material
- D21H19/36—Coatings with pigments
- D21H19/38—Coatings with pigments characterised by the pigments
- D21H19/42—Coatings with pigments characterised by the pigments at least partly organic
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H19/00—Coated paper; Coating material
- D21H19/36—Coatings with pigments
- D21H19/44—Coatings with pigments characterised by the other ingredients, e.g. the binder or dispersing agent
- D21H19/52—Cellulose; Derivatives thereof
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H23/00—Processes or apparatus for adding material to the pulp or to the paper
- D21H23/02—Processes or apparatus for adding material to the pulp or to the paper characterised by the manner in which substances are added
- D21H23/22—Addition to the formed paper
- D21H23/32—Addition to the formed paper by contacting paper with an excess of material, e.g. from a reservoir or in a manner necessitating removal of applied excess material from the paper
- D21H23/34—Knife or blade type coaters
Landscapes
- Paper (AREA)
- Control Of Driving Devices And Active Controlling Of Vehicle (AREA)
Abstract
The present invention relates to a process of manufacturing a high bulk, low weight paper product produced by using a high level of groundwood containing sheet, blade coating with specifically formulated coatings then passing the paper web between two extended-nip calenders, one calender for each side of paper. As a result, densification of the resulting coated paper product is reduced, while maintaining stiffness and opacity comparable to heavier weight sheets.
Claims (23)
1. A process for manufacturing a lightweight, high bulk coated paper, comprising the steps of:
(a) creating a fiber furnish comprising mechanical pulp and chemical pulp;
(b) forming a paper web from the fiber furnish;
(c) removing water from said web;
(d) applying a coating having a weight of at least 2.0 pounds per 3300 square feet per side onto each surface of said web to form a coated web having a moisture content greater than 5.5%, and a caliper greater than 2.8 mils;
(e) passing the coated web through two extended-nip calenders, with each side of the paper facing a heated roll and treated with one of said calender nips, and wherein each calendering nip is formed by a calender roll having a surface temperature of at least 300°
F and a backing shoe having a width of at least 30 mm. the nip providing loading of at least 1000 pounds per linear inch; and whereby the calendered paper has a caliper preservation greater than 75%.
(a) creating a fiber furnish comprising mechanical pulp and chemical pulp;
(b) forming a paper web from the fiber furnish;
(c) removing water from said web;
(d) applying a coating having a weight of at least 2.0 pounds per 3300 square feet per side onto each surface of said web to form a coated web having a moisture content greater than 5.5%, and a caliper greater than 2.8 mils;
(e) passing the coated web through two extended-nip calenders, with each side of the paper facing a heated roll and treated with one of said calender nips, and wherein each calendering nip is formed by a calender roll having a surface temperature of at least 300°
F and a backing shoe having a width of at least 30 mm. the nip providing loading of at least 1000 pounds per linear inch; and whereby the calendered paper has a caliper preservation greater than 75%.
2. A process as in Claim 1 wherein the coating comprises a platy kaolin as a pigment.
3. A process as in Claim 2 wherein said kaolin pigment has a fine particle size distribution characterized in that at least 85% of said particles are less than 2 microns and at least 50% of said particles are less than 0.5 microns, based upon particle counting using a Sedigraph particle size analyzer.
4. A process as in Claim 2 wherein said kaolin pigment has a platy morphology characterized as both fine and coarse particles having a shape factor greater than 15.
5. A process as in Claim 2 wherein said kaolin pigment has a platy morphology characterized as both fine and coarse particles having a shape factor of about 20 to 27.
6. A process as in Claim 1 wherein said furnish comprises at least 40%
mechanical pulp.
mechanical pulp.
7. A process as in Claim 6 wherein said furnish comprises about 60 to 80%
mechanical pulp.
mechanical pulp.
8. A process as in Claim 1 wherein said coating has a weight of 2.0 to 6.0 pounds per 3300 square feet per side.
9. A process as in Claim 1 wherein said coated web has a moisture content greater than 6,5%.
10. A process as in Claim 1 wherein said coated web has a moisture content greater than 7.0%.
11. A process as in Claim 1 wherein said coating comprises a hollow plastic pigment; a kaolin pigment; a calcined kaolin clay; a titanium dioxide pigment; a synthetic latex binder; and a synthetic thickener, or a co-binder including carboxymethylcellulose or acrylic acid based or associative based thickeners.
12. A process as in Claim 11 wherein said coating also comprises precipitated calcium carbonate or ground calcium carbonate.
13. A process as in Claim 11 wherein said hollow plastic pigment is present in an amount of at least about 2% by weight of the total amount of pigment.
14. A process as in Claim 11, wherein said hollow plastic pigment is present in an amount of about 3 to 5% by weight of the total amount of pigment.
15. A process as in Claim 11 wherein said kaolin pigment has a fine particle size distribution characterized in that at least 85% of said particles are less than 2 microns and at least 50% of said particles are less than 0.5 microns, based upon particle counting using a Sedigraph particle size analyzer.
16. A process as in Claim 11 wherein said kaolin pigment has a platy morphology characterized as both fine and coarse particles having a shape factor greater than 15.
17. A process as in Claim 11 wherein said kaolin pigment has a platy morphology character-ized as both fine and coarse particles having a shape factor of about 20 to 27.
18. A process as in Claim 11 wherein said kaolin pigment is present in an amount of at least 70% by weight of the total amount of pigment.
19. A process as in Claim 11 wherein said kaolin pigment is present in an amount of 80% to 100% by weight of the total amount of pigment.
20. A process as in Claim 1 wherein the coating is preferably applied using a blade coater or a metering size press.
21. A process as in Claim 1 wherein the calender is a shoe nip calender, said shoe nip width being in the range of from about 40 mm to about 80 mm, and calendering temperature is at least 300° F, and nip loading at 1700-2400 pli.
22. A process as in Claim 1 wherein said calendered paper has a basis weight of 28 to 38 pounds per 3300 square feet and exhibits a 75 degree TAPPI gloss of 35% or above and a caliper of at least 2.15 mils.
23. A process for manufacturing a super high bulk, offset lightweight coated paper, compris-ing (a) creating a fiber furnish comprising at least 40% mechanical pulp;
(b) forming a paper web from the fiber furnish;
(c) removing water from said web;
(d) applying a coating using a blade coater at coat weights of at least 2.0 pounds per 3300 square feet, per side onto each surface of said web to form a coated web having a moisture content of at least 5.5%; and (e) passing the coated web through two extended-nip calenders, with each side of paper facing a heated roll and treated with one of said calender nips; whereby each calendering nip is formed by a calender roll having a surface temperature of at least 300° F and a backing shoe nip having a width of at least 30 mm, the nip providing loading of at least 1000 pounds per linear inch (pli), and whereby the calendered paper has a caliper preservation greater than 75%, wherein the coating comprises:
(i) hollow plastic pigment, in an amount of at least about 2% by weight of the total amount of pigment;
(ii) kaolin pigment in an amount of at least about 70% by weight of the total amount of pigment, said kaolin pigment having a fine particle size distribution characterized by at least 85% of said particles are less than 2 microns and at least 50% of said particles are less than 0.5 microns, and a platy morphology characterized as both fine and coarse particles having a shape factor greater than 15, preferably 20-27;
(iii) titanium dioxide in an amount of at least about 2% by weight of the total amount of pigment;
(iv) calcined kaolin in an amount of at least 5% by weight of the total amount of pigment;
(v) synthetic latex in a concentration of at least about 12 or more parts by weight of the total amount of pigment;
(vi) synthetic thickener in a concentration of at least about 0.05 or more parts by weight of the total amount of pigment; and wherein the finished coated paper has a basis weight of 28 to 38 pounds per 33 square feet, exhibits a 75 TAPPI gloss of 35% or above, has a caliper of at least 2.15 mils, gives a 17-27%
higher caliper, has up to 22% bulk improvement relative to a supercalendered 30 pounds/3300 square feet LWC, and has improved brightness, opacity and printing gloss.
(b) forming a paper web from the fiber furnish;
(c) removing water from said web;
(d) applying a coating using a blade coater at coat weights of at least 2.0 pounds per 3300 square feet, per side onto each surface of said web to form a coated web having a moisture content of at least 5.5%; and (e) passing the coated web through two extended-nip calenders, with each side of paper facing a heated roll and treated with one of said calender nips; whereby each calendering nip is formed by a calender roll having a surface temperature of at least 300° F and a backing shoe nip having a width of at least 30 mm, the nip providing loading of at least 1000 pounds per linear inch (pli), and whereby the calendered paper has a caliper preservation greater than 75%, wherein the coating comprises:
(i) hollow plastic pigment, in an amount of at least about 2% by weight of the total amount of pigment;
(ii) kaolin pigment in an amount of at least about 70% by weight of the total amount of pigment, said kaolin pigment having a fine particle size distribution characterized by at least 85% of said particles are less than 2 microns and at least 50% of said particles are less than 0.5 microns, and a platy morphology characterized as both fine and coarse particles having a shape factor greater than 15, preferably 20-27;
(iii) titanium dioxide in an amount of at least about 2% by weight of the total amount of pigment;
(iv) calcined kaolin in an amount of at least 5% by weight of the total amount of pigment;
(v) synthetic latex in a concentration of at least about 12 or more parts by weight of the total amount of pigment;
(vi) synthetic thickener in a concentration of at least about 0.05 or more parts by weight of the total amount of pigment; and wherein the finished coated paper has a basis weight of 28 to 38 pounds per 33 square feet, exhibits a 75 TAPPI gloss of 35% or above, has a caliper of at least 2.15 mils, gives a 17-27%
higher caliper, has up to 22% bulk improvement relative to a supercalendered 30 pounds/3300 square feet LWC, and has improved brightness, opacity and printing gloss.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US42918002P | 2002-11-26 | 2002-11-26 | |
| US60/429,180 | 2002-11-26 | ||
| PCT/IB2003/005385 WO2004048692A2 (en) | 2002-11-26 | 2003-11-25 | Process for producing super high bulk, light weight coated papers |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2503966A1 true CA2503966A1 (en) | 2004-06-10 |
| CA2503966C CA2503966C (en) | 2011-10-18 |
Family
ID=32393516
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA2503966A Expired - Fee Related CA2503966C (en) | 2002-11-26 | 2003-11-25 | Process for producing super high bulk, light weight coated papers |
Country Status (10)
| Country | Link |
|---|---|
| US (1) | US20040099391A1 (en) |
| EP (1) | EP1565614B1 (en) |
| JP (1) | JP2006507420A (en) |
| KR (1) | KR20050086818A (en) |
| CN (1) | CN1723317A (en) |
| AT (1) | ATE366338T1 (en) |
| AU (1) | AU2003302443A1 (en) |
| CA (1) | CA2503966C (en) |
| DE (1) | DE60314771T2 (en) |
| WO (1) | WO2004048692A2 (en) |
Families Citing this family (23)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US6866906B2 (en) | 2000-01-26 | 2005-03-15 | International Paper Company | Cut resistant paper and paper articles and method for making same |
| CN100392182C (en) * | 2000-06-27 | 2008-06-04 | 日本制纸股份有限公司 | Printing coated paper |
| RU2387752C2 (en) | 2002-09-13 | 2010-04-27 | Интернэшнл Пейпер Компани | Paper of improved rigidity and bulk and method of its producing |
| US20050031805A1 (en) * | 2003-06-17 | 2005-02-10 | Fugitt Gary P. | Pigment selection for photographic base stock |
| US20050028951A1 (en) * | 2003-06-17 | 2005-02-10 | Brelsford Gregg L. | Smooth base stock composed of nonstandard fibers |
| US20050032644A1 (en) * | 2003-06-17 | 2005-02-10 | Brelsford Gregg L. | Binder selection for coated photographic base stock |
| DE102004062618A1 (en) | 2004-12-24 | 2006-07-06 | Voith Paper Patent Gmbh | screed assembly |
| KR101329927B1 (en) | 2005-03-11 | 2013-11-20 | 인터내셔널 페이퍼 컴퍼니 | Compositions containing expandable microspheres and an ionic compound, as well as methods of making and using the same |
| JP4692736B2 (en) * | 2005-05-27 | 2011-06-01 | 王子製紙株式会社 | Coated paper for printing and method for producing the same |
| KR20070028249A (en) * | 2005-09-07 | 2007-03-12 | 오지 세이시 가부시키가이샤 | Coated paper |
| US8349443B2 (en) | 2006-02-23 | 2013-01-08 | Meadwestvaco Corporation | Method for treating a substrate |
| CA2547276A1 (en) * | 2006-05-19 | 2007-11-19 | Abitibi-Consolidated Inc. | Coated mechanical pulp paper |
| JP2009097098A (en) * | 2007-10-12 | 2009-05-07 | Kao Corp | Method for producing coated paper |
| CN102137878B (en) | 2008-08-28 | 2014-06-18 | 国际纸业公司 | Expandable microspheres and methods of making and using the same |
| AR075381A1 (en) * | 2009-02-10 | 2011-03-30 | Unicamp | USE OF PARTICLES OF PHOSPHATE, POLYPHOSPHATE AND METAPHOSPHATE, OF ALUMINUM IN PAPER COATING APPLICATIONS. |
| US9545810B2 (en) | 2013-01-11 | 2017-01-17 | Hewlett-Packard Development Company, L.P. | Low grammage recording medium |
| WO2018089739A1 (en) * | 2016-11-11 | 2018-05-17 | Westrock Mwv, Llc | Paperboard with low coat weight and high smoothness |
| CN106522014A (en) * | 2016-12-22 | 2017-03-22 | 东升新材料（山东）有限公司 | Micro-coating light paper for improving printing effect and preparation method of micro-coating light paper |
| US10961663B2 (en) | 2017-01-25 | 2021-03-30 | Westrock Mwv, Llc | Paperboard with low coat weight and high smoothness |
| US10443410B2 (en) * | 2017-06-16 | 2019-10-15 | General Electric Company | Ceramic matrix composite (CMC) hollow blade and method of forming CMC hollow blade |
| CN107245903B (en) * | 2017-07-04 | 2018-12-11 | 吉林化工学院 | A kind of preparation method of low cost logistics waybill |
| JP2023502524A (en) | 2019-11-22 | 2023-01-24 | アプビオン リミテッド ライアビリティ カンパニー | Water-dispersible direct thermal or inkjet printable media |
| CN114855508A (en) * | 2022-05-19 | 2022-08-05 | 海南金海浆纸业有限公司 | Ultrahigh-bulk single-sided coated paper and production process thereof |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| US4749445A (en) * | 1984-05-18 | 1988-06-07 | S. D. Warren Company | Method of finishing paper utilizing substrata thermal molding |
| DE3920204A1 (en) * | 1988-10-31 | 1990-05-10 | Escher Wyss Gmbh | METHOD FOR SMOOTHING A PAPER OR CARDBOARD SHEET |
| US5400707A (en) * | 1992-10-09 | 1995-03-28 | Champion International Corporation | Apparatus for finishing a continuous sheet of paper |
| US5283129A (en) * | 1992-10-21 | 1994-02-01 | Champion International Corporation | Light weight paper stock |
| JPH0881899A (en) * | 1994-09-13 | 1996-03-26 | New Oji Paper Co Ltd | Coated paper and high gloss printed matter |
| SE9500949L (en) * | 1995-03-16 | 1996-07-08 | Korsnaes Ab | Coated cardboard for shaped articles, production line for production of coated cardboard, method for making coated cardboard and ways to reduce the cracking propensity when folding a coated cardboard |
| US6254725B1 (en) * | 1997-06-20 | 2001-07-03 | Consolidated Papers, Inc. | High bulk paper |
| US6203307B1 (en) * | 1997-08-28 | 2001-03-20 | Champion International Corporation | System for finishing surface of a web of paper having an improved continuous finishing belt |
| JP4154752B2 (en) * | 1998-04-23 | 2008-09-24 | 王子製紙株式会社 | Dull coated paper |
| FI104745B (en) * | 1998-06-25 | 2000-03-31 | Valmet Corp | Method and apparatus for calendering paper and cardboard |
| US6287424B1 (en) * | 1998-09-22 | 2001-09-11 | International Paper Company | Method for finishing paperboard to achieve improved smoothness |
| US6332953B1 (en) * | 1998-10-02 | 2001-12-25 | International Paper Company | Paper product having enhanced printing properties and related method of manufacture |
| SE9804346D0 (en) * | 1998-12-16 | 1998-12-16 | Valmet Corp | Method and apparatus for calendering paper |
| FI991108A (en) * | 1999-05-14 | 2000-11-15 | Valmet Corp | Method and apparatus for the manufacture of calendered paper or calendered paperboard |
| JP2000336593A (en) * | 1999-05-31 | 2000-12-05 | Nippon Paper Industries Co Ltd | Coated paper for printing |
| NL1012468C2 (en) * | 1999-06-29 | 2001-01-02 | Ver Bedrijven Van Den Berg Hee | Soil probe with optical data transmission. |
| US6531183B1 (en) * | 1999-07-28 | 2003-03-11 | Meadwestvaco Corporation | Method of producing high gloss paper |
| US6465074B1 (en) * | 1999-08-25 | 2002-10-15 | Albany International Corp. | Base substrates for coated belts |
| FI20000671A0 (en) * | 2000-03-22 | 2000-03-22 | Valmet Corp | Multi-type calendars and calendaring arrangements |
| JP3342470B2 (en) * | 2000-05-24 | 2002-11-11 | 三菱重工業株式会社 | Calendar device |
| FI115405B (en) * | 2000-06-20 | 2005-04-29 | Metso Paper Inc | Calendering method especially for pre-calendering and paper processing line |
| FI115543B (en) * | 2000-06-20 | 2005-05-31 | Metso Paper Inc | Procedure for preliminary calendering, post-processing and apparatus for carrying out the processes |
| JP2002055414A (en) * | 2000-08-09 | 2002-02-20 | Mitsubishi Paper Mills Ltd | Base for image material and method of manufacturing the same |
| FI20011291A (en) * | 2001-06-18 | 2002-12-19 | Metso Paper Inc | Process and paper machine for making coated paper |
| US20030085012A1 (en) * | 2001-09-07 | 2003-05-08 | Jones J Philip E | Hyperplaty clays and their use in paper coating and filling, methods for making same, and paper products having improved brightness |
| US6808559B2 (en) * | 2002-02-26 | 2004-10-26 | Imerys Pigments, Inc. | Kaolin clay pigments suited to rotogravure printing applications and method for preparing the same |
-
2003
- 2003-07-10 US US10/618,053 patent/US20040099391A1/en not_active Abandoned
- 2003-11-25 JP JP2004554833A patent/JP2006507420A/en active Pending
- 2003-11-25 CA CA2503966A patent/CA2503966C/en not_active Expired - Fee Related
- 2003-11-25 EP EP03811840A patent/EP1565614B1/en not_active Expired - Lifetime
- 2003-11-25 AT AT03811840T patent/ATE366338T1/en active
- 2003-11-25 KR KR1020057009425A patent/KR20050086818A/en not_active Application Discontinuation
- 2003-11-25 DE DE60314771T patent/DE60314771T2/en not_active Expired - Lifetime
- 2003-11-25 WO PCT/IB2003/005385 patent/WO2004048692A2/en active IP Right Grant
- 2003-11-25 AU AU2003302443A patent/AU2003302443A1/en not_active Abandoned
- 2003-11-25 CN CNA2003801042016A patent/CN1723317A/en active Pending
Also Published As
| Publication number | Publication date |
|---|---|
| EP1565614B1 (en) | 2007-07-04 |
| WO2004048692A2 (en) | 2004-06-10 |
| CA2503966C (en) | 2011-10-18 |
| US20040099391A1 (en) | 2004-05-27 |
| JP2006507420A (en) | 2006-03-02 |
| AU2003302443A1 (en) | 2004-06-18 |
| CN1723317A (en) | 2006-01-18 |
| DE60314771T2 (en) | 2008-03-06 |
| DE60314771D1 (en) | 2007-08-16 |
| WO2004048692A3 (en) | 2004-07-29 |
| ATE366338T1 (en) | 2007-07-15 |
| KR20050086818A (en) | 2005-08-30 |
| AU2003302443A8 (en) | 2004-06-18 |
| EP1565614A2 (en) | 2005-08-24 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| EEER | Examination request | ||
| MKLA | Lapsed |
Effective date: 20171127 |