Bio Based Nano Particle technology Latex in Paper and Paper board coating IPPTA Work Shop- 10 th &11 th December 2015 PK Mittal Suresh babu HC Joshi

Why paper is coated ??

Coating Ingredients

Coating Ingredients, Dry weight %

What is Nano Particle Technology  Starch Occurs in Nature in Various plant forms and consists of Microscopic granules for energy storage by plant.  Starch requires water, heat and caustic chemicals to dissolve. It has resulted Starch Solutions have high viscosity at Low solids, a Property that limits their use in Industrial applications.  Nano technology Process that removes the native granular structure and reduce the Particle size diameter from approx. ~ 30 micron( 0.03mm) to 0.1 micron (0.0001mm) Or 100nm.  Starch normally has a density of 1.6g/cc and Nano particle latex has a density 1.0g/cc which is similar to the SB Latex.

Process of Nano Particle Technology  The Fundamental design of bio latex is similar to that of Synthetic latexes but the Process of Producing them is completely different.  Synthetic latex is Produced from Petroleum based monomers in an aqueous Emulsion polymerization process.  The bio latex nano particle are Produced from 20 to 30 micron starch particles Using a reactive extrusion process.  The Process converts starch into a thermoplastics melt that is transformed into an Agglomerate of dry crosslinked biopolymer nano particles

Bio Latex road Map

Structure of Bio latex

Bio-based Latex Powder

Bio-Latex binder Particle Size

Comparison of Bio-latex with Other binders

Structural Differences of Bio-latex and others

Bio –latex Nano Particles film Formation

Bio –latex Nano Particles under Shear and Pressure Schematics showing the deformation of water-swollen crosslinked biopolymer nanoparticles under high shear rates Paper Coating Particles ClayClay CaCO3CaCO3 latexbiolatex binderbinder Shearing Under Shear biolatex binder: deforms & deswells Schematics showing the deformation under high shear rates of biobased latex in the presence of pigment and latex particles The Deformation of Water-Swollen Crosslinked Biobased Nanoparticles under Shear and Pressure Leading to Less Dilatancy and Better Runnability

Bio –latex Characteristics Swelling and de-swelling responsive to concentration, temperature, etc. Deformation under shear and pressure, resulting in less dilatancy and better high-speed blade runnability Higher %effective solids and volume solids leading to better coating holdout, fiber coverage, and coating smoothness Less shrinkage leading to higher gloss and more open and opaque coatings

Bio –latex Nano Particles On Machine Performance

Savings Of Bio-latex

Savings of Bio-Latex

Case Study :1 Lab Study report of Bio-Latex Bio Based Latex Properties S.NoParameterUnitsSample Bio based Latex 1Moisture%9.0 2 p H 9.5 3Viscosity at 55 o C # 2 (25% solid)cps170 Coating Solution Properties(Prepared in Lab) S.NoParameterUnits Trial 1 Trial 2 Trial 3 Trial 4 Trial 5 1Coating starch% Biobased Latex% Latex% Cross linker As such%0.75 5Caustic Flakes%0.35 6Thickner% Solid%62 8Viscositycps pH Water retention test with GWR g/m2 in 2 minute

Lab study report of Bio-Latex Properties of Board coated with this prepared solution,Then Top coat Coating solution (Prepared in plant) is applied.( Un calendered) 11 Gloss% PPSmicron Dry Pick Imedium viscosity)m/s Print Gloss% Linting - OK

Plant trial report of Bio-Latex ControlTrial ChemicalsPrecoatTopcoatPrecoatTopcoat coat GCC PCC Clay Coating Starch Latex Biolatex nano- particle Coating Weight12±212± 112±212± 1 Viscosity (100 RPM) Solid content64-66%63-64%64-66%63-64% WRV

Final Product report with Bio Based Latex ItemsUnitControlTrial Gramg/m TopBrightness% BackBrightness% SmoothnessS PPSum Gloss%4042 Stiffness(MD)m N Stiffness(CD)m N Burst(Top) Dry Pickm/s Internal BondJ/m Ink Gloss%8890 Ink Transfer%52

Comparision of Latexes interms of Eco green

LCIA

Carbon Neutrality Bio latex binders provide a neutral carbon foot print, Petroleum-based SB and SA Latex binders are “carbon Positive” because they contain “old” carbon. For every one Million Pounds of SB and SA latex substitute by bio latex, this intrinsically offers a reduction of 3.3 Million pounds( 1515Mt) in C02 Emissions i;e equivalent of Eliminating CO2 emissions from approx. 400 cars.

Bio latex benefits

Summary  Freight Saving ( not having to ship 50% water)  Energy Savings (Higher Solids coating Formulation)  Fiber reduction ( Enhanced Stiffness)  Enhanced recyclability  Carbon Tax Credit

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