Lightweighting trends and opportunities in coated board Mark Rushton Matti Lares Editor Pulp & Paper International Senior Technology Manager, Valmet Lightweighting Savings by reducing basis weight while maintaining all functional properties of packaging Sustainable way to develop whole packaging industry and its supply chain Being competitive against other packaging materials 2 © Valmet Customer Days | Matti Lares, Mark Rushton Packaging market today Total size 600 billion EUR/a 2% Packaging is a growing business 7% – 3 to 6 % annually Fiber-based packaging products are based on: 15% 36% – Coated boards – Container boards – Packaging papers Fiber-based products are renewable and recyclable Production of fiber-based materials is energy-efficient and the products have a low carbon footprint 3 © Valmet Customer Days | Matti Lares, Mark Rushton 40% Fiber-based Plastics Source: PIRA & Metsa Board Metals Glass Others Why lightweighting? Towards today’s challenges in coated board market 1. Competition with other packaging materials 2. Competition within coated board business due to capacity expansions → Continuous cost reduction 3. Sustainability Functional properties have to be maintained while reducing weight 4 © Valmet Customer Days | Matti Lares, Mark Rushton Same performance with lighter product Making 1 million biscuit packages requires approx. 32,000 m2 of board: 30 Taber CD stiffness, mNm 25 20 15 10 All having same stiffness properties of 10 mNm. 5 0 150 200 250 300 350 400 450 500 550 600 Basis weight, g/m2 5 High bulk FBB FBB 7.9 tons 9.3 tons © Valmet Customer Days | Matti Lares, Mark Rushton SBS High bulk WLC 10.8 tons 12 tons WLC 12.8 tons 650 Get more with less resources Improved sustainability throughout the supply chain Less packaging waste Raw material and energy reduction Disposal Coated Board Producer Sustainability Converter Consumer Consistency of packaging material Reduction of weight Packer Retailer Efficient operations and protection 6 © Valmet Customer Days | Matti Lares, Mark Rushton Runnability Brand Owner Brand values Quality of different packaging board grades 4,5 4,0 PPS s10 [µm] 3,5 WLC 3,0 2,5 2,0 Europe 1,5 Asia SBS 1,0 FBB 0,5 0,9 7 © Valmet 1,0 1,1 1,2 1,3 Customer Days | Matti Lares, Mark Rushton 1,4 1,5 1,6 Bulk, [cm³/g] 1,7 1,8 1,9 2,0 Excellent as always – lighter than ever! Introducing Alaska Plus lightweight GC2 board with unparalleled benefits Modernization of PM 4 ...OR Same280stiffness t 300 t Lower basis weight 10 M 10,7 M Better smoothness ALASKA 300g/m2 ALASKA PLUS 280g/m2 ALASKA PLUS 280g/m2 1,000,000 m2 10,000,000 boxes 1,000,000 m2 10,000,000 boxes 1,070,000 m2 10,700,000 boxes Source http://internationalpaper.com/Apps/Alaska-Plus/cost-saving.html 8 © Valmet Customer Days | Matti Lares, Mark Rushton Case: IP Kwidzyn BM 4, Poland Rebuild enables upgrade from Alaska to Alaska Plus The production of Alaska Plus was started after the modernization project in 2014 Using the latest technology in board making, they have been able to lower the basis weights of this product at the same stiffness and bulk Specification – Alaska vs Alaska Plus 1,95 1,90 1,85 1,80 + 12 % Bulk 1,75 1,70 1,65 1,60 1,55 1,50 200 220 240 260 280 300 320 340 360 Basis weight Alaska 9 © Valmet Customer Days | Matti Lares, Mark Rushton Alaska Plus Source: http://internationalpaper.com/Apps/AlaskaPlus/technical.html and RISI Extremely high bulk Rebuild at Simpele mill Weight reduction achieved without stiffness and loss of strength Source: http://www.metsaboard.com/News/newslisting/Pages/BirdsEyereducespackagingweightfollowingwrapproject.aspx 10 © Valmet Customer Days | Matti Lares, Mark Rushton Case: Metsä Board Simpele BM 3, Finland More, Better and Lighter Deep cooperation with Valmet since 2002 After 1st rebuild (2006): 225.000 tpa Before rebuild (2006): 170.000 tpa On start-up (1970): 85.000 tpa Machine supplied by Valmet 11 © Valmet Rebuild scope: • • • • • • • • Customer Days | Matti Lares, Mark Rushton New hydraulic headboxes Film size press Metal belt calender Air dryers Center-driven reel Belt-supported winder Roll wrapping machine Yankee was bypassed After 2nd rebuild (2011): >300.000 tpa Rebuild scope: • • • • Rebuild of forming section Shoe press Rebuild of drying section Yankee was replaced by drying cylinders Source: http://www.metsaboard.com/products/Product_news/Pages/Morelightweight-Simcote.aspx and Fiber&Paper magazine 3/2006 Same stiffness with lowest weight WINS! Xiandong Ji, General Manager of Zhuhai S.E.Z. Hongta Reheng Paper Co., Ltd., 12 © Valmet Customer Days | Matti Lares, Mark Rushton Source: Results-magazine 2/2013 What are the solutions? Right selection of fibers combined with Fiber optimization modern refining technology 13 © Valmet Customer Days | Matti Lares, Mark Rushton Everything starts with fiber! Furnish has the greatest effect on lightweighting Improve filler ply bulk and retain good internal bonding – Selection of furnish / fibers – Higher freeness – Good bonding with minimum density increase Increase modulus of elasticity of top & bottom plies and keep low porosity – Optimized basis weight distribution and HW/SW ratio – High tensile with minimum porosity increase 14 © Valmet Customer Days | Matti Lares, Mark Rushton What are the solutions? Right selection of fibers combined with Fiber optimization modern refining technology Aqua layering headbox 15 © Valmet Customer Days | Matti Lares, Mark Rushton Increased internal strength of filler ply What are the solutions? Right selection of fibers combined with Fiber optimization modern refining technology 16 © Valmet Aqua layering headbox Increased internal strength of filler ply Shoe pressing Improved smoothness: less calendering and lower coat weight Customer Days | Matti Lares, Mark Rushton Shoe press as a smoothing press Traditionally a roll press – – – – Bulk losses Felt marking Limited linear load Runnability issues With shoe smoothing press longer dwell time = optimized bulk – smoothness – dryness combination after press More smooth base board for coating section, lower calendering loads and less bulk reduction 17 © Valmet Customer Days | Matti Lares, Mark Rushton Rebuild results Before After Press loads (kN/m) 800 900 - 800 900 650 Pre-calendering (kN/m / °C) 30 / 180 30 / 180 Final calendering (kN/m / °C) 35 / 160 40 / 160 Coat weight (g/m2) 30 27 PPSs10 (µm) 2.0 1.3 Density (g/cm3) 930 840 Burst (kPam2/g) 2.3 2.3 What are the solutions? Right selection of fibers combined with Fiber optimization modern refining technology 18 © Valmet Aqua layering headbox Increased internal strength of filler ply Shoe pressing Improved smoothness: less calendering and lower coat weight Multi-layer curtain coating Better coating coverage enables reduced use of raw materials Customer Days | Matti Lares, Mark Rushton Multilayer curtain coating Each coating layer can be adjusted to desired function and cost • Functional coating layer possibility • Possibility for both thin and thick – Printability – Barrier layers, e.g. for the food industry – Coverage coating layers – Thin layer capability, even 2 g/m2 – Thick layer capability, up to 30 g/m2 Different function for each layer 19 © Valmet Customer Days | Matti Lares, Mark Rushton Electron microscope Visible difference with curtain coating Blade coating (15 g/m2) Base paper 20 © Valmet Customer Days | Matti Lares, Mark Rushton Curtain coating (15 g/m2) Case example of raw material savings Case: Cartones Ponderosa PM 1, Mexico “Our customers are asking for better printability, which means better surface uniformity. We also needed to achieve cost savings to be more cost competitive while maintaining a good balance with quality.” Saul Guzman Espinoza, Operations Director, Cartones Ponderosa 21 © Valmet New coat weight split and coating formulation → Total coat weight decreased by 4 g/m2 → Annual savings more than USD 3 million → Further opportunities to reduce white fibers Customer Days | Matti Lares, Mark Rushton What are the solutions? Right selection of fibers combined with Fiber optimization modern refining technology 22 © Valmet Aqua layering headbox Increased internal strength of filler ply Shoe pressing Improved smoothness: less calendering and lower coat weight Multi-layer curtain coating Better coating coverage enables reduced use of raw materials Metal belt calendering Excellent calendering results without sacrificing bulk Customer Days | Matti Lares, Mark Rushton Metal belt calender can reduce the amount of raw materials by 4–8% Standard 255 g/m² FBB Metalbelt 230 g/m² FBB OPTITOPO ROUGHNESS ANALYSIS Gradient image (40 mm × 40 mm) 23 © Valmet Customer Days | Matti Lares, Mark Rushton What are the solutions? Right selection of fibers combined with Fiber optimization modern refining technology 24 © Valmet Aqua layering headbox Increased internal strength of filler ply Shoe pressing Improved smoothness: less calendering and lower coat weight Multi-layer curtain coating Better coating coverage enables reduced use of raw materials Metal belt calendering Excellent calendering results without sacrificing bulk Aqua cooling calendering Cooled web does not compress permanently Customer Days | Matti Lares, Mark Rushton Huge benefits shared equally Stiffness remains the same when basis weight drops from 285 to 250 g/m2 Note: The decrease in cost caused by raw material savings has been equally shared between board producer and converter For board producers EUR 14 million more sales For converters 6% lower purchasing cost 25 © Valmet Customer Days | Matti Lares, Mark Rushton Board producer – Production 200,000 tonnes/year Produced board tonnage remains the same – 702 million m2 800 million m2 Converter – Annual need for board surface area 500 million m2 – Required tonnage 142,500 tonnes 125,000 tonnes Lightweighting is a clear opportunity Choose your path! Valmet is committed to moving your performance forward 26 © Valmet Customer Days | Matti Lares, Mark Rushton
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