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

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

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

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.

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

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

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

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%

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

Case study 1: Coated paperboard Capacity: 100,000 tonnes per year Speed: 500 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

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

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.

Case study 1: Coated paperboard Brookfield viscosity of coating color

Case study 1: Coated paperboard Stiffness of coated paperboard

Case study 1: Coated paperboard Gloss of coated paperboard

Case study 1: Coated paperboard Pick resistance of coated paperboard

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

Case study 2: LWC paper Capacity: 230,000 tonnes per year Speed: 1080 mpm Coater type: Sym-sizer Paper grade: LWC paper Main quality concerned: Gloss and dry pick resistance

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

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.

Case study 2: LWC paper Gloss of LWC paper

Case study 2: LWC paper Pick resistance of LWC paper

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