Changing Requirements of Raw Materials for Automatic Plants. By Ram Kumar Sunkara Brown Kraft Industries Ltd

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1 Changing Requirements of Raw Materials for Automatic Plants By Ram Kumar Sunkara Brown Kraft Industries Ltd

2 The issue is not about packaging, but about polishing; for packaging leaves the original product in a crude form, while polishing involves value-addition addition 2

3 Two Paths to Quality We can follow two paths to achieve quality optimized corrugated board. We can follow M A P route, or We can follow P A M route. 3

4 M A P route to quality High Quality Medium Quality M A Machine Adhesive Lower Quality P Paper Quality Optimized Board 4

5 P A M route to quality High Quality Medium Quality P A Paper Adhesive Lower Quality M Machine Quality Board 5

6 P A M route All semi automatic operations follow this route. There are also many automatic operations which follow this route. 6

7 What route you want to follow? Do you want to follow Pam? Pamela Anderson PAM for short. Like her your board will be sexy, and, Unaffordable. Very expensive. Quality not optimized. PAM 7

8 What route you want follow? Do you want to follow a map? Map will lead you to your destination. It will chart the path to most cost effective optimized board. It is the right path. Make your choice. MAP 8

9 If you do not want to follow PAM Pay attention to raw materials used. Paper Adhesives What changes are required. Where do we stand in global scenario. 9

10 The Environment The environment will remain a major issue for the packaging industry. Issues involving recycling, reducing the amount of solid waste, source reduction will remain on the agenda of all governments. The driving forces are threefold - the consumer, commercial interests and government legislation. Getting the economics "right" is the key ingredient of a successful packaging environment policy. 10

11 Changing Requirements These environmental pressures are changing the requirements of raw materials. In paper Switching back from white top to brown top Source reduction in form of down gauging. Lowering Liner and fluting GSM, yet maintain the quality parameters. High ring crush liner High CMT medium. 11

12 Global requirements Let us look at one paper parameter only CMT value of medium. Parameters like RCT have been discussed in past and we have seen improvements in this the last couple of years. Mills are now concentrating on RCT give out spec sheet in that respect. However no work is being done on CMT values. 12

13 Minimum Flat Crush values Globally there are minimum standards for flat crush values of corrugated boards. Flat crush value of corrugated board is related to CMT value of medium. Let us look at some minimum global requirements. 13

14 Belgium GSM range for medium 112 to 140 Minimum flat crush value for 100 flutes per meter is 1.5 bar or 146 kpa. 14

15 France For all GSM, the arithmetic mean of 5 single measurements should not be less than 145 kpa. 15

16 U. K Minimum GSM of fluting medium is 112 Minimum flat crush test values are For A flute: 140 kpa For B flute: 180 kpa For C flute: 165 kpa 16

17 Italy The minimum flat crush values For single wall: 117 kpa For double wall: 127 kpa 17

18 Observation The GSM range for fluting medium is 112 to 140 on an average. Most countries specify minimum flat crush values of 140 kpa and above. What are the values we are getting using local papers. 18

19 Observation on Indian Paper A flute board with 150 GSM 20 BF paper in fluting: Observed FCT 79 to 88 kpa A flute board with 180 GSM 20 BF paper in fluting: Observed FCT 94 to 102 kpa B flute board with 180 GSM 24 BF paper in fluting: Observed FCT 190 to 203 kpa 19

20 Observation on Indian Paper These readings are not at all encouraging. There has to be improvement in these values. At least 20% reduction in GSM with a corresponding increase of 20% in FCT. Why FCT is important? 20

21 Impact of FCT on ECT Lower FCT values will mean the board will get crushed in converting operations like printing, die cutting etc. Loss of caliper means loss of ECT Loss of ECT means, loss of compression strength. 21

22 Caliper Loss Vs ECT E C T in lbs / in Caliper loss in mm 22

23 Pin Adhesion Vs ECT E C T in lbs / in P A T in lbs 23

24 Adhesive requirements We have seen that increasing PIN adhesion values will give more than 10% increase in ECT values. Below 30 lbs PIN adhesion values, the board will de-laminate. We can get increased PAT values by using modified starch adhesives. Need to look at special additives. 24

25 Thank you, Have a nice day id: ramkumarsunkara@hotmail.com

The science behind the heart of corrugated MEDIUM

The science behind the heart of corrugated MEDIUM Tom Staal MQ/OE MEDIUM FROM THE USER PERSPECTIVE THE SCIENTISTS Institute of Paper Chemistry McKee, Gander, Wachuta 1961 Edge Crush Test developed 1963