Starch As A Driver In Papermaking Development
Starch as a DriverIn Papermaking DevelopmentA. Ragauskas*, Y. Deng*, P. Jones**, D. White**Institute of Paper Science and TechnologyGeorgia Institute of Technology**Imerys1
Advantages of Using Filler in Paper Increased filler content in paper will improvepaper optical properties– Brightness– Opacity– Print quality Increased filler content in paper will reducepapermaking materials costs– Pulp price: 250-400/ton– Filler cost (clay or PCC): 100-130/ton Increase water drainage, drying rate2
Potential Problemsof Using Filler in Paper Effects on wet and dry end operations– Retention– Water clarification– Dusting Effects on sheet properties– Sheet two-sidedness– Reduced paper strength– Reduced bulk– Linting3
Past Research in Filler Modification New filler development– Fibril fillers– Pretreatment of fillers Coating polymer on filler surface– Polymers used in the literature are relativelyexpensive– Some polymers can cause environmental problems– Effect on paper properties, such as causingunnecessary sizing, increasing recycling difficulty4
ObjectiveDevelop new bonding fillers to improveexisting sheet properties whiledecreasing fiber costs5
Small fiber-fiber contact area: low paper strengthLarge fiber-fiber contact area: high paper strengthConceptual diagram showing impact of filler/ aggregatesize on strength6
Our Approach: FillerTreatment Using StarchfiberIn traditionalpapermaking StarchOur approachfiberCoatedFillerFillerStarch adsorbed on fillerStarch coated on filler7
Approach Using Starch CoatingFiller aggregatescoated with starchand with suitableparticle sizeLarger particle size:decreased contact areabetween fiber and fillerIncreased mechanicalretentionImproved bonding(increased bondedarea vs. untreated clay)8
Filler Treatment with StarchClayFiller starch waterFillerStarch cooked with orwithout clayStarchFiller dissolved starch waterDried (feed range of20-50% solids)Starch-coated filler2.5 or 5% starch based on clayDuring drying, starch forms networkClay is encapsulated with starch moleculesStarch-coatedClay20-40 µm; starch coatedCoated starch relativelywater-insoluble9
Clay ModificationClayClay with 5% coatedcationic starch10
Clay ModificationClay with 5% coatedraw potato starchClay with 25% coatedraw potato starch11
Starch dissolving, %( on starch coatedon clay)Starch Dissolving Profile of 2.5% Starch Modified Clay(stirring speed 1200 rpm, clay consistency 10g/L)2525 , Cornstarchmodified clay2025 , potatostarchmodified clay1555 , cornstarchmodified clay1055 , potatostarchmodified clay50020406080100 120 140160 180 200Stir time, min.12
Starch Swelling Power vs. Time and Temperaturecorn starch,25 Swelling power,g wet film/g drystarch14corn starch,55 12potato starch,25 potato,55 1086420020406080Time, min.Dried starch absorbs water, swells, deforms– indication of behavior on claywhich would enhance bonding13
Lab ResultsRing crush vs. filler contentRing crush,lbf Starch coated and dried on claysurface can increase paperstrength significantly (10-15%)vs. use of unmodified clay– Ring crush– Similar optical properties Different starches (corn, potato,cationic starch) gave similareffects Starch amount as little as 2.5%of the filler to give significantpositive effect85pure clay80corn starch modifiedclaypotato starch modifiedclaypotato starch clay7570656055500102030Filler content,%14
Lab Results (Continued) Confirmed spray-dried starch coated clay has increasedpaper strength vs. unmodified clay (handsheets)– Also bulk and stiffness improvement– Modified clay does not reduce clay’s ability to increasepaper brightness Potential to use low cost clay and low grade starch toproduce high strength paper/board with high filler content15
Laboratory 0102030Tensile index (Nm/g)Tensile index (Nm/g)Handsheet Tensile 0010Filler content (% )Before Calendering2030Filler content (%)CalenderedControl: 5% starch based on unmodified clay;i.e., at 10% clay in sheet: 0.5% starch in sheet (10 lb/t)16
Ring Crush (lbf), GMRing Crush, Calendered 015100102030Filler content (%)Can add at least 10-15% modified clay and get same ring crush17
Clay CharacterizationClay surface area and particle sizeClay2.5%Corn5%Corn2.5%Potato7.5%PotatoSurface area (m2/g)10.77.97.08.28.3Particle size (micron)Percentage less than given particle 519961014.2583235.262123Modified clays: lower surface area, larger particle size 18
Pilot Results Modified clay filler produced using pilotspray dryer at IPST, at IMERYS Pilot mill trial at Herty Foundation withspray dried clay from Imerys spray dryer Confirmed scale-up– Sheet properties– Dewatering improvement with clayaddition19
Spray Dryer EvaluationClay Viscosity– To assesspotential forspray drying– Control: 50%solidsunmodified clay– Modified clay:20-50% solidsrangeinvestigated10050% potato20-5corn20-5potato9080Viscosity (cP) Shear viscositymeasured forcontrol clay andmodified clay7060504030201000200400600Shear Rate20
Spray Dryer EvaluationSample20% Clay20-2.5Corn20-5Corn20-2.5Potato20-5Potato50% Clay30-2.5Corn35-2.5Corn40-2.5Corn45-2.5CornFeed 5Gas Temp 0210120210120210120210120Mass yield(%)72.099.088.174.082.179.796.995.197.892.6 Results: modified clay can be spray dried up to40-45% clay21
Spray – Dried Starch-Coated Clay – Handsheet TrialsTensile Index vs. Filler ContentModified Clay– IMERYS (Atlanta, GA)– Modified clay coated withprecooked 2.5% corn starch viaspray drying of 40% clay slurry– Particle size (light scattering, insuspension) increased withmodified clay vs.conventional clay 55Orig. Clay50Tensile Index (Nm/g) 454035Furnish– SW kraft pulp, kappa 105, Inland– Pulp was beaten to C.S.F. 350 ml3005101520Filler Content (%)Handsheets– TAPPI method, 180 g/m2 , CPAMretention aid.Ring Crush Index vs. Filler Content at Different CPAM Levels17O rig. C la y ( 0 - 2 ppm C P A M )16RIng Crush Index (Nm/g) 2.5Cor nS pra y- D rie d M o d. C la y, 2 .5C o rn ( 0 - 2 ppm C P A M )151413121102468Filler Content (%)10122214
Spray-Dried Starch-Coated ClayHerty Pilot TrialCONTROL(No clay)ORIGINAL CLAYStnd clay(High AR) 10 % 20 %STARCH COATEDCLAYFillerNoneFurnishReslushed liner furnish (IP), mixed SW/HW, CSF 500-550 mlPMSingle ply; BW 170 g/m2 ; 75 fpmChemicals(pH 6-7)Corn starchCorn starch (2.5%)RA: CPAM (Percol175) 1 ppmMod. Clay (1.8%starch; spraydried@20% solids ) 10 % 20 %RA: CPAM23
Spray-Dried Starch-Coated Clay- Herty Pilot TrialGM Ring Crush Index vs. Clay ContentModified clay4013Original clayGM Ring Crush index (Nm/g)Tensile Index (Nm/g), GM4535302520Original ClayModified Clay121110987051015Clay content (% )20250510152025Clay Content in Sheet (%)Over 10% increase in tensile and ring crush with modified vs. conventional clayDecrease in strength vs. unfilled control (starch content less than target)target24
Herty Pilot Trial : Bulk, Stiffness3.51.6Modified clayModified clay3Bulk (cm /g)Stiffness (mNm), GMOriginal clay1.51.41.31.2Original clay3.02.52.01.5051015Clay content (% )202505101520Clay content (% )Bulk maintained at 10% modified clay contentStiffness reduced only slightly at 10% modified clay content;stiffness increases with bonding, but is more sensitive to sheet25thickness (Moberg)25
Brightness35Modified clayBrightness (ISO)30Original clay252015100510152025Clay content (% )Similar brightness increase with modified andconventional clay26
Effect of Dispersion TimeGM Ring Crush Index vs. Clay Content- Effect of Dispersion Time4513Original clay4020 hrs Mod. ClayGM Ring Crush Index (Nm/g)Tensile Index (N m/g), GMModified clay353025Original ClayModified Clay20 hrs. Mod. Clay1211109820051015Clay content (% )2025705101520Clay Content in Sheet (%)Long dispersion time had no effect on tensile, but possibleeffect on ring crush2725
10% original clay10% modified clayConsistent with particle size measurements: IPST (laser- orig. clay: 9.5 µm, modified clay: 38.228µm); Imerys (Sedigaph: mod. clay slightly coarser)
20% unmodified clay20% modified clay29
Effect of Clay on DewateringEffect of Clay on Sheet Dewatering60Dryness out of PressConsistency (%)50403020Clay, Couch CMod. Clay, Couch CClay, Press CMod. Clay, Press CDryness off Couch1000102030405060Sheet Ash Content (% )Significant effect of clay or modified clay on dewatering.30
Linerboard CapacitiesLinerboard capacitiesin USA are close toKaolin deposits in SESource:P Ince, 2001 USDA FPL31
Logistics Uniqueto SE USA PaperIndustryAugustaMaconKlteBniaol32
Summary Modified filler platform developed Potential to use low cost clay and low grade starch toproduce high strength paper/board with high fillercontent– Decreased fiber and processing costs Evaluating options for modified clay production–––Lower cost clay sources and processingProcess development and scale up of modified fillerSupport of further pilot filler production and applicationstesting33
Acknowledgement Georgia TIP3 Program for financial support Imerys34
Confirmed spray-dried starch coated clay has increased paper strength vs. unmodified clay (handsheets) - Also bulk and stiffness improvement - Modified clay does not reduce clay's ability to increase paper brightness Potential to use low cost clay and low grade starch to produce high strength paper/board with high filler content
Jung Sun Hong 2 Summary o Food chemistry, carbohydrates/starch chemistry o A specialist in modification techniques of starch Chemical, physical, and enzymatic method For specific application in food system and industrial purposes o A strong research background in fundamental aspect of carbohydrates polymers/starches and their derivatives
Starch based trays are not transparent. Other packaging products Starch based mate-rials are frequently used in loose fill foams for transport packaging. Another ap-plication is in service ware like cups, plates and cutlery. Biodegradable films, with starch as a matrix, were developed and reinforced with wheat and corn hulls.
Starch is a natural polymer which possesses many unique properties and some shortcoming simultaneously. Some synthetic polymers are biodegradable and can be tailor-made easily. Therefore, by combining the individual advan-tages of starch and synthetic polymers, starch-based completely biodegradable polymers (SCBP) are potential for applica-
The starch is separated from the raw sugar by precipitation with alcohol and dissolved in a calcium chloride solution. The starch in solution is reacted with iodine and the colour of he starch/iodine complex is measuredt spectrophotometrically at a wavelength of 600 nm. A standard graph prepared using a sta
The starch is separated from the sample by precipitation with alcohol and dissolved in a calcium chloride solution. The starch in solution is reacted with iodine and the colour of the starch/iodine complex is measured spectrophotometrically at a wavelength of 600 nm. A standard graph prepared using a sta
Natures Own 100% whole wheat Publix/Kroger 2 slices 1 starch EXTRA STRICT: Nature's Own life bread Publix/Kroger 40 calories, 2 slices 1 starch Natures Own Sandwich Rounds Publix/Kroger 1 1 starch/2 minis 1 starch Weight Watchers 100% who
Mono-Carbohydrates Di, poly-Carbohydrates Elmhurst College High Fructose Corn Syrup Sweeteners Starch - Iodine Test Chemistry Department Blood Glucose Test Sugar and Tooth Decay Virtual ChemBook Click for larger image Starch - Iodine Starch: Plants store glucose as the polysaccharide starch. The cereal
What does a (-) Reducing Sugar test look like: _ Starch Positive Control 1) Label a test tube "S ( )" (which stands for Starch Positive Control). 2) Add 2 ml of Starch solution to the tube. Negative Control 1) Label a test tube "S (-)" (which stands for Starch Negative Control).
