Productivity and Quality To The Rotogravure Chain
Productivity and Quality To The Rotogravure Chain
Productivity and Quality To The Rotogravure Chain
Presented by Mikko Likitalo (Global Vice-President, Technology) Chris Nutbeem, Janet Preston, Graham Pring
Outline
Imerys and the Rotogravure Industry Pigment effects on productivity Pigment effects on paper & print quality Conclusions
As of December 31, 2005, the Pigments for Paper business groups sales totalled EUR 755 million, contributing to 25% of Imerys' 2005 consolidated sales.
PCC Production - 16 Plants ~900 mtpa Paper Capacity GCC Production - 29 Plants ~3000 mtpa Paper Capacity Kaolin Production - 4 Deposits ~3300 mtpa Paper Capacity
Kaolins
Imerys has a broad portfolio in Kaolins, GCC and PCC. Imerys solutions for paper applications are founded on technical and economical optimisation based on in-depth multipigment understanding Imerys has the broadest portfolio in kaolins
Carbonates
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Pigment Strategy
Focus is High Quality at Lowest Possible Cost Carbonate Onsite processing at the paper mills to reduce formulation cost Kaolin Efficient use of wide reserve base to produce required kaolin portfolio
Europe is the largest producer of rotogravure papers, with around one quarter of the 38.6 million tonnes of printing and writing papers that are produced in the region. Papers for rotogravure:
80% of European SC papers 35% of the European LWC
The SC and LWC rotogravure markets are of particular importance to Imerys due to the high suitability of our UK and Brazilian kaolin assets for these applications. The steady growth of rotogravure in Europe has prompted Imerys to invest specifically for this market segment.
Others 77%
Imerys is the largest single supplier with significant market share in European Rotogravure In excess of 500 kt pigment sales supporting ~2 million tonnes paper production Provides strong base for development to meet future needs in Rotogravure
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SC
Intramax Intramax Intrafil Intrafil Filler M Filler M 1985 1985 Superclay Superclay
LWC
Imerys has continuously developed its filler and coating clays for SC and LWC Rotogravure applications over the past 10-15 years. We can now offer pigments with high brightness, high shape and steep particle size distributions and low abrasion.
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New coating and filling products from Brazil: Capim RG and Capim SBF
Unbeatable runnability with high shape, brightness & coarse/steep psd Suitable for production of high brightness papers. Over 80 Million investment in refining capacity, energy efficient dewatering and logistics, Oct 2007.
Through continuous investment we aim to become an even more important partner to our paper customers
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Productivity Productivity
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Significant cost reductions without major process /technology changes is hardly possible !!!
Chemistry 1/5 of Total Cost: 90 % Coating 10 % Other
Pigment solutions need to focus on productivity as well as paper quality if cost-performance is to be maximised
Source Gron & Likitalo PTS 2005
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245 m
Abrasion of Fillers
Wire Abrasion Relative to Chalk 200% 150% 100% 50% 0% Chalk Marble PCC Kaolin
100% 69% 12% 730%
Einlehner Abrasion g/m2 Standard Intrafil C Imax 60 Capim SBF 60-120 50-70 40-60 10-20
Processing developments and development of fillers from naturally less abrasive reserves has led to kaolin fillers with exceptionally low abrasion.
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Runnability in Coating and Finishing Runnability in Coating and Finishing Good Water Retention -- High Shape Factor Pigments Good Water Retention High Shape Factor Pigments Good High Shear Rheology -- Control of Fines Fraction Important Good High Shear Rheology Control of Fines Fraction Important Blade wear -- Mineral Purity is important Blade wear Mineral Purity is important Friction Control -- Mineralogy important Friction Control Mineralogy important
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Base Paper
Production Costs
Investment Costs
MSP can give cost & productivity benefits in rotogravure Reduced strength requirement enables Roto quality to be produced with de-inked pulp and/or increased filler Imerys has pioneered pigment concept development for MSP Roto - currently in Industrial use
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Performance Attributes
Smoothness Porosity Strength Gloss and Coverage Brightness and Whiteness Opacity Ink Demand & Hold-out Missing Dots
Key variables are shape, size and steepness of distribution Key quality measures are optics and print quality
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Key Properties
Missing dots:
Related to contact
Print Evenness:
Related to dot gain/pore structure
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Kaolin SF 30
Kaolin SF 10
Pigment shape is critical in controlling porosity and roughness in both coated and uncoated gravure Increasing brightness by using carbonate fillers and coating pigments puts greater emphasis on the kaolin to maintain printability.
GCC
PCC
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Multi-Pigment Concepts with Optimised Kaolins Can Give the Best Balance of Properties in High Bright SC
High Bright SC
GCC
Light Scatter
Standard SC
Standard SC Kaolin
Key trade-off is generating scatter and optics without adversely impacting gloss and ink demand
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High
Brightness
Key trade-off is generating brightness/Opacity without adversely impacting gloss & print quality.
Kaolin/Talc
Good
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However, paper producers can also extract value from high quality raw materials for reducing total processing cost. For example:
High shape kaolins in filling and coating can enable low cost carbonate use for similar printing performance and brightness at reduced total bleaching cost. Steep pigments can help paper strength enabling increased loadings or greater use of recycled fibre. High brightness fillers and coating pigments can always reduce bleaching costs.
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Conclusions Conclusions
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Summary
Imerys has a long history of innovation & development of pigments for rotogravure applications backed up by a strong market position We understand the the role pigments play in controlling productivity and quality in filling and coating applications. This together with a wide portfolio of products and strong R&D has lead to pigment solutions that give clear value to the papermaker.
Coarse kaolin fillers with low abrasion for acid SC Fine kaolin fillers for neutral SC High shape, high brightness coatings clays for LWC Complemented by a broad range of PCC and GCC products for coating and filling
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Future Challenges
Energy Costs
Increasing energy costs for pigment producers and paper makers together with a tendency to flat paper pricing will change the way in which pigments are developed and used.
With our research and global resources, we are ready to meet these challenges
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