1. KLIC 10: NEW GENERATION COATING ADDITIVES AS TOTAL BINDER REDUCTION IN COATING FORMULA AND RENEWABLE COATING BINDERS
Akamanuwatr, S. and Wanakhachornkrai, P.
SMS CORPORATION, CO., LTD. (THAILAND)
Total pages = 24

2. Contents Introduction Development background
Case study 1: Coated paperboard
Case study 2: LWC paper
Conclusion

3. Introduction Starch is a renewable resource Glucose Starch
Source: CIAT and Designed by Freepik.com

4. Introduction
Availability of starch as natural resources: graph total world native starch production
Source: LMC International. Trends in the Global Starch Industry. Presented in World tapioca Conference 2011.

5. Introduction Coating paper and board formulation
Pigments: GCC/ Clay
Binder: Latex
Co-binder: Coating starch
Thickener: CMC
Additive: KLIC 10 (grafted starch)  reducing total binder

6. Development background
Focus on LHH concept L
Less total binder H
High starch part
High solid coating

7. Development background
Trend: What happen when more starch is incorporated in the coating color?
Drawback
Benefit
High low-shear viscosity
Improve water retention
High high-shear viscosity
Improve dry pick strength
Cracking Tendency
Improve stiffness

8. Development background
Grafted starch is a multiple modifications tapioca starch derivative with unique properties
It is a low molecular weight starch which contained small number of short polar side chain of degraded tapioca amylose and amylopectin backbone
Grafted starch is made by tightening starch granules with specific cross linker in the first stage followed by degradation and then polar short side chains are installed
Charge characteristic of grafted starch is anionic
Application of the grafted starch in coating formulation at 1- 2 pph could be able to reduce total binder content by up to 25%

9. Development background
Flexible film
Excellent tack properties
Starch
Grafted starch
Grafted starch
Starch
+ Grafted starch
Latex + Starch
+ Grafted starch

10. Case study 1: Coated paperboard
Capacity: 100,000 tonnes per year
Speed: mpm
Coater type: Applicator rolls with a metering bar
Paper grade: Coated paperboard, double coat
Main quality concerned:
Stiffness, brightness, gloss, fold crack resistance, and IGT dry pick resistance

11. Case study 1: Coated paperboard
Coating formulation and properties of coating color (lab)
Formulation
%Solid
Reference
Trial 1
Trial 2
Part
1.Pigment
- CaCO3 75
100
2.Binder
- Latex 50 9 6
7.5
- Coating starch 40 2
- Additive: Grafted starch 95
1.5 1
3.Additive
- Thickener 25
0.15
Coating properties
Unit
% Solid content 64 pH
Brookfield (100 rpm); 0 hr (35°)
(cPs)
490
555
527
HERCULES FF 6600 rpm; 0 hr (25°) 36 43
AA GWR,gsm 1.5 bar, 120 sec; 0 hr
(g/m2)
144
137
132

12. Case study 1: Coated paperboard
Coating formulation during production trial
Formulation
% Solid
Reference formula
Trial formula
Part
1.Pigment
- CaCO3 75
100
2.Binder
- Latex 50 9
6.5
- Coating starch 20 2
- Grafted starch 95
1.2
3. Additives: dyes, thickener, OBA, biocide, etc.

13. Case study 1: Coated paperboard
Brookfield viscosity of coating color

14. Case study 1: Coated paperboard
Stiffness of coated paperboard

15. Case study 1: Coated paperboard
Gloss of coated paperboard

16. Case study 1: Coated paperboard
Pick resistance of coated paperboard

17. Case study 1: Coated paperboard
Fold crack resistance of coated paperboard
Formula
Digital scan
Enhanced image analysis
Reference
Trial run

18. Case study 2: LWC paper Capacity: 230,000 tonnes per year
Speed: mpm
Coater type: Sym-sizer
Paper grade: LWC paper
Main quality concerned:
Gloss and dry pick resistance

19. Case study 2: LWC paper
Coating formulation and properties of coating color (lab)
Formulation
%Solid
Reference
Trial 1
Trial 2
Part
1.Pigment
- Kaolin clay
100
2.Binder
- Latex 50 8 6 5
- Coating starch 40
- Additive: Grafted starch 95 1
1.5
3.Additive
- Dispersant
0.3
Coating properties
Unit
% Solid content 60 pH 9
Brookfield (100 rpm); 0 hr (35°)
(cPs)
560
627
610
HERCULES FF 6600 rpm; 0 hr (25°) 35 37
AA GWR,gsm 1.5 bar, 120 sec; 0 hr
(g/m2) 93 84

20. Case study 2: LWC paper Coating formulation during production trial
% Solid
Reference formula
Trial formula
Part
1.Pigment
- Clay
100
2.Binder
- Latex 50 8 6
- Coating starch 35 5
- Grafted starch 95 1
3. Additives: dispersant, dyes, OBA, biocide, etc.

21. Case study 2: LWC paper
Gloss of LWC paper

22. Case study 2: LWC paper
Pick resistance of LWC paper

23. Conclusion
Information obtained from laboratory study is useful for paper mill to make a decision on production trial
Coating colors containing the grafted starch were applicable not only with paperboard but also with lightweight paper
Rheological properties of coating color, machine run-ability and pick resistance of coated papers produced were comparable to corresponding reference formulations that contained higher total binder
Paper mill could save production cost substantially by application of the starch
LHH concept combined with application of the grafted starch has been proofed to be valid and operable in resource- and cost-wise strategies for a long term coated paper production