Developments in use of MFC for End Market Applications

Specialty Papers US – 2nd October 2018

Tom Larson
Technology Implementation Manager

• A Technology Joint Venture between Imerys and Omya
  • Partners commercialize FiberLean^® MFC Products
  • FiberLean provides technical support to partners in commercialization of FiberLean^® MFC products
  • FiberLean develops FiberLean^® MFC products and applications
  • Global reach across all relevant industries

What is MFC?

MFC Properties

• Very high aspect ratio
• Very high surface are
• Increased hydrogen bonding potential
• Highly viscous when suspended in water
• Wide variety of applications

Constraints

• High energy costs
• Equipment capability
• Transportation

FiberLean^® MFC is the solution to these constraints

FiberLean is the leading global producer of MFC

• Industrial process
• Robust, reliable and scalable plants
• Multiple customer implementations on-going
  • Satellite plants for paper and packaging customers
  • Total installed capacity 50k dmt/y of FiberLean^® MFC (10k dmt/y fibrils)
• Growing portfolio of Intellectual Property and Applications

Range of composite types are possible

• FiberLean process has the flexibility to be used with a range of fiber/mineral types – including recycled.
• Intrinsic properties of both minerals and fibers are tailored to each application. MFC content can be varied.

Product forms

• Slurry – Available supply via satellite plant built on-site
  • Low solids (~2% fiber solids) due to high viscosity
  • For trials: delivered in IBC tanks or road tanker
• Press cake – Available for trials, delivered in IBC bags
  • ~15% fiber solids ‘crumble’, requires re-dispersion
• High Solids – Future supply via merchant plant
  • ≥25% fiber solids ‘pellets’, requires re-dispersion

Product forms

Regulatory Clearance

• Cleared through Environment Canada, Health Canada, US EPA and US FDA (FCN 1582, 1887, for 5 wt.% fibrils in packaging board)​
• BfR application filed for consideration under recommendations XXXVI, XXXVI/1, XXXVI/2, and XXXVI/3

FiberLean^® MFC in Paper

• When added to paper-based products, the intrinsic properties of MFC/filler composites are utilized
• High surface area fibril network provides:
  • More hydrogen bonding sites = improved strength
  • Closed sheet structure = improved coating hold-out and surface properties
• Which in turn provides opportunities for:
  • Use of additional filler for improved optical properties and reduced costs
  • Improved paper properties

Higher filler loading in uncoated woodfree papers using MFC-mineral composites

• Full scale UWF results with 1 and 2% MFC addition

Despite some loss in Tensile, higher filler levels are possible due to the enhanced wet web strength

Note: These are pilot trial results using 450 ml CSF, 30% Pine / 70% Euca furnish and GCC filler

Improved base paper to make better coated papers using MFC-mineral composites

• Full scale UWF results with 1.5% MFC addition

MFC in the Base Improves Coating Hold-out

• 80 g/m² woodfree paper was prepared on a pilot paper machine
  • 70% Eucalyptus / 30% Pine (450 CSF)
  • 20% GCC filler
  • 0% and 2% MFC
  • No sizing added
• Paper was coated with:
  • GCC / Kaolin formulation (10 pph Latex)
  • Coat-weights between 6 to 14 g/m²
  • Supercalendared
• Less coating penetration when using MFC due to smoother and more closed surface structure of the base

Improved properties at equal coat-weight or equivalent properties at lower coat-weights when using MFC

FiberLean^® MFC in Packaging

• Similarly to MFC/mineral composites in paper, we see similar attributes when applied to packaging:
  • Enhanced bonding strength
  • Enhanced opacity/coverage of outer plies
  • Improved surface properties/porosity of outer plies
• Dematerialization and improved printability opportunities are presented

MFC/Mineral composites in folding boxboard

Strength from MFC can be successfully traded for better bulk/stiffness and higher productivity

• The “adjustment” made here is making the mid-ply pulp coarser, i.e. reducing the refining energy.

Folding Boxboard application, full scale results

• Filler increase and basis weight reduction in top/back layers:
  • 2.25% MFC in each
  • +10% filler in each, 4 g/m² of top layer and 3 g/m² of bottom replaced by middle layer
  • Conditions chosen to maintain stiffness
  • Machine speed, filler retention and runnability maintained
• Specification maintained at a reduced cost:
  • Bending stiffness and brightness unchanged
  • Significantly improved smoothness

White Top Liner application, full scale results

• Filler increase and basis weight reduction:
  • 2.5% MFC in white layer
  • +9% filler in the white layer
  • 10 g/m² of top layer replaced by brown layer
  • Conditions chosen to maintain brightness
  • Machine speed, filler retention and runnability maintained
• Specification maintained at a reduced cost:
  • Minor changes in strength properties
  • Large reduction in air permeability
  • 40% increase in Scott Bond
  • Potential for higher filler increase and brightness

Two approaches to using MFC-mineral composite to make white top liner

NPD – Wet-end coating on top of the wire section

• MFC-mineral composite applied as a low solids slurry on top of the still consolidating base layer.
• The composite has the ability to stay on the surface without penetrating into the base.
• The top layer is drained using existing foils and vacuum boxes.
• Pressing and drying as normal for the combined coating and base board.
• The top layer is strong and has good adhesion while offering coverage, low porosity, smoothness and excellent printability.

NPD – Pilot trial application of 30 g/m² dry MFC-mineral composite at 500 m/min on top of 70 g/m² base

• High mineral content / MFC composite layers applied at the wet-end provide:
  • Excellent surface properties and printability = an alternative way to produce WTL
• Low mineral content / MFC composite layers applied at the wet-end provide:
  • Mechanical property re-enforcement
  • Excellent surface properties (closed, smooth structure) – ideal for coatings / specialty coatings (barrier etc.)
  • Barrier properties of MFC

Consumers are demanding alternatives to plastic…

Is this an opportunity for Specialty Papers/MFC?

Summary