1. EFFECT OF BIO-POLYMER LATEX ON COATED PAPER Submitted by : N. Srikanth Date : 18 -5-2009

2. Topics 1. Overview 2. Objectives 3. Methodology 4. Results 5. Conclusion 6. Recommendations 7. Question & Answer Submitted by : N. Srikanth

3. Why is Paper Coated? Overview Submitted by : N. Srikanth

4. Why is Paper Coated? 1. Printability - Improved Smoothness - Uniform Coating - Better Ink Receptivity 2. Visual Properties - Improved Brightness - Better Opacity and Gloss 3. Functionality - Reduction in ink consumption - Better Glue ability Submitted by : N. Srikanth

5. Different Coating methods Base SheetCoatingBase SheetCoating Level Coating - Good smoothness Contour Coating- Better Coverage Submitted by : N. Srikanth

6. Coating Components Pigment (85-95 wt %) ( GCC and Clay) Binder (5-15%) Water Sodium Hydroxide Lubricant Defoamer Thickener ( Rheology Modifier ) Dye Optical Brightener ( OBA ) Cross-linker Dispersant Submitted by : N. Srikanth

7. Synthetic Binders Different types of Synthetic polymers –Styrene butadiene –Polyvinyl acetate –Vinyl acrylic –Acrylic latex –Polyvinyl alcohol Synthetic binders helps to improve final sheet properties like –Gloss –Smoothness –Printability Submitted by : N. Srikanth

8. What is Biopolymer latex Biopolymer NanoparticlesEx. Native Starch Granules Effective surface >200 m 2 /g (est.) 30 µm 200 nm Size reduced 300-600x Submitted by : N. Srikanth

9. Advantage of Biopolymer latex Effect on Environment - Substitute to synthetic latex - Reduced GHG emission - Clean and lean manufacturing - Satellite production plant close to customer - No volatile organic compound - Reduced carbon foot print - Easy to start the production process Addition of Bio polymer latex improves final sheet property like, - Increase in dry pick strength, - Reduces print mottle, - Increase in pore volume, good glue ability. - Increase in paper stiffness. Submitted by : N. Srikanth

10. Preparation of Biopolymer latex Submitted by : N. Srikanth Source :Tappi paper 360 magazine.

11. Water-Swollen, Crosslinked Biopolymer Core: V(Core) Bound and Adsorbed Biopolymer Shell: V(Shell) The Hypothesized Structure of a Water- Swollen, Crosslinked Biopolymer Nanoparticle The biopolymer latex has a small hairy water soluble starch polymer in the surface, sterically stabilized protective colloidal layer which is cross linked with insoulblizer like glyoxal or AZC. Submitted by : N. Srikanth

12. Dispersion range of latex Particle Size Measurements 10 nm 100 nm 1000 nm 1 µm 10,000 nm 10 µm 100,000 nm 100 µm Bio- polymer range of emulsions Bio- polymer in Dry paper coat PVA c SB R Starch Submitted by : N. Srikanth

13. Film formation of Bio polymer latex Free-Flowing Dispersion Entanglement & in-solubilization at the particle interfaces Drying/Compaction Gelation/ Immobilization Water liberates, but biopolymer cores do not collapse and form “nano-cellular foam-like” film, yielding air voids Particle Deformation & Further Coalescence Consolidation With Partial Collapse Aqueous dispersion of water-swollen biopolymer nano-particles Stiff water-swollen cross-linked biopolymer nano-particles do not collapse much during film formation. Consequently, film shrinkage is much less than starch and more like S/B latex, yielding better gloss and improved opacity under optimized calendering conditions. Submitted by : N. Srikanth

14. Objectives Submitted by : N. Srikanth

15. 1) Replacing Synthetic binder SB and SA latex with Bio polymer latex LA 40 in an increment of 25% up to 100%,while keeping other coating receipe components constant. 2) Comparing properties of coating color, surface and printing properties of coated paper i.e. Control formulation vs. combination of SB,SA latex and Bio polymer latex formulation. Submitted by : N. Srikanth

16. Methodology Submitted by : N. Srikanth

17. Test formulation Reference(Control Sample ) DescriptionunitsSB LatexSA latexBio latex PigmentParts100 synthetic latexParts12 Bio polymer latexParts000 CMCParts0.5 0 TotalParts112.5 112 Set #1 ( SB latex +Bio polymer latex) Descriptionunits#1#2#3 PigmentParts100 synthetic latex(styrene butadiene)Parts963 Bio polymer latexParts369 CMCParts0.5 TotalParts112.5 Set #2 ( SA Latex +Bio Polymer latex) Descriptionunits#1#2#3 PigmentParts100 synthetic latex(styrene acrylate)Parts963 Bio polymer latexParts369 CMCParts0.5 TotalParts112.5 Submitted by : N. Srikanth

18. Calculation of chemicals dosage as per recipes Make down of recipe Dispersion of chemical Chemical preparation Check Printing properties. Testing of coated paper 1.Coat weight 2.Brightness 3.opacity 4.IGT pick 5.PPS 6.Porosity 7.caliper 8.Gloss Drying of coated paper Test for base paper 1.Basis weight 2.Moisture 3.Ash % 4.Thickness 5.Density 6.Porosity 7.PPS 8.Tensile 9.Brightness 10.opacity Additive addition 1. Synthetic binder 2. Lubricant. 3. OBA Preparation of binder/Co binder 1.CMC.(10% solution) 2.Ready to use Bio-polymer latex (40% solution) Making coated paper. Testing of coating color. 1.pH value. 2.Solids content 3.Viscosity (cps) 4.Water retention Chemical testing 1.pH value 2.Solids content 3.moisture 4.Viscosity 5.Appearance Super calendering of coated paper Testing of coated paper 1. Brightness 2. Opacity 3. IGT pick 4. PPS 5. Porosity 6. Caliper 7. Gloss Target coat weight 11 +/- 0.5 gsm Testing of coated paper 1. Print Gloss 2. Wet pick 3. Wet Repellence 4. Set off 5. ISIT 6.Print density Submitted by : N. Srikanth

19. Results Submitted by : N. Srikanth

20. Water retention of coating color Increased water retention by 50% to 100% Submitted by : N. Srikanth Bio polymer and SB latex

21. Wet Void Volume - coating color Increase in Wet void volume value by 6% to 25%. Submitted by : N. Srikanth

22. Viscosity of coating color Increase in viscosity of color by 50%- 100%. Submitted by : N. Srikanth

23. PPS roughness of SC paper Marginal increase in PPS value by 5% - 10% Submitted by : N. Srikanth

24. Brightness of SC paper No difference in brightness value of coated paper Submitted by : N. Srikanth

25. Opacity of SC paper No or slight difference in the opacity value of the paper Submitted by : N. Srikanth

26. Dry pick of coated paper Increase in Dry pick strength by 40%. Submitted by : N. Srikanth

27. Delta gloss of printed paper Increase in Delta gloss (print snap) by 50% Submitted by : N. Srikanth

28. Customer SavingsReference#1#2#3 PigmentParts100 synthetic latexParts12963 Bio polymer latexParts0369 CMCParts10.50.20 TotalParts113112.5112.2112 Basepapergsm40 Coat weightgsm20 Totalgsm60 MT/yrTotal binder Cost (US$ Million) Paper production 300,000 $23.40$22$21.10$20.30 Estimated Annual savingsUS $M$1.40$2.30$3.00 %6%11%15% Bio latex Substitution level0%24%49%75% Cost saving Sheet Potential annual cost saving is from 6% to 15%. Submitted by : N. Srikanth

29. Environment consideration Fossil content 1% Mean Bio based Result: 1* as per ASTM D 6866 Proportions Bio based Vs Fossil Based indicated by 14 C content for SB latex Mean Bio based Result: 99* as per ASTM D 6866 Proportions Bio based Vs Fossil Based indicated by 14 C content for Bio latex Bio basedcontent 99% Bio based content 1% Fossil content 99% For every 1 million lb of SB /SA latex 3.3 million pounds (1,515 metric tons) of CO2 emissions Biopolymer 37.5% substitution level of Industry wide would reduce CO2 emissions by 2.27 MMT equating to 600,000 cars off the road Submitted by : N. Srikanth

30. FeaturesBenefits 1Substitute for latex binderSimilar performance in coating colors 2Requires no cookingEnergy (steam) and labor savings 3Modified biopolymer from starchCarbon neutral and Renewable resource 4Lower latex costSignificant annual savings, Price stability, not linked to varying petroleum prices 5Viscosity & ultra-high shear rheology = synthetic latex Simple adjustment of existing coating recipe – similar or better runnability 6Reduce rheological modifierAdditional potential saving 7Available dry or liquidFreight savings & formulation flexibility 8RecyclabilityReduced batch time and saving in power. 9Effluent systemNo shock load and good nutrient for the system. Benefits of Bio polymer latex Submitted by : N. Srikanth

31. Conclusion Submitted by : N. Srikanth

32. Increased water retention by 50% to 100% Increase in viscosity of color by 50%- 100%. Marginal increase in PPS value by 5% - 10%. Increase in Delta gloss (print snap) by 50% Increase in Dry pick strength by 40%. Increase in Wet void volume value by 6% to 25%. No difference in brightness value of coated paper Potential annual cost saving is from 6% to 15%. Submitted by : N. Srikanth Conclusion

33. Properties of coating colorBio-polymer Latex LA 40Synthetic Latex(SB,SA)LA40 /Synthetic Latexes(SB/SA) Ease of Formulation  Water Retention  Air volume %  Density  Sediment volume  Viscosity  Properties of coated paper Bio-polymer Latex LA 40Synthetic Latex(SB,SA)LA40 /Synthetic Latexes(SB/SA) Gloss  Porosity  PPS  Thickness  porevolume  K&N  Dry Strength  Wet Strength  wet repellence  Print Gloss  Brightness w/o OBA  Print Density  Opacity  Ink tack rise   Increase  No Change  Decrease Submitted by : N. Srikanth Summary

34. Recommendations Submitted by : N. Srikanth

35. 1) In all coating mill, all pre-coat formulation 100% Bio polymer latex LA 40 can be substituted in place of Synthetic binder SB and SA latex 2) In top coating formulation 25 -50% Bio polymer latex LA-40 can be substituted in place of synthetic SB and SA latex. Submitted by : N. Srikanth

36. Question ??? & Answer !!! Submitted by : N. Srikanth

37. Thanks Dr. Mousa Nazhad, Asian Institute of Technology. Dr.Esa Lehtinen, Asian Institute of Technology Dr.Esa Viljakainen, Asian Institute of technology. Dr.Robert Hill, IMERYS Ltd, UK. Mr.Edwald Beivi, UPM Research centre, Changzhou,China. Ms.Zhang Homing, UPM Research center Changzhou, China. Dr.H.Komoldin, Advanced Agro limited. Thailand. Ms.Daroung Inthong, Siam Modified Starch co, Ltd. Submitted by : N. Srikanth