Paper and Paperboard Converting

Transcription

1 Papermaking Science and Technology a book series covering the latest technology and future trends Book 12 Paper and Paperboard Converting Second Edition Totally updated version Book editor Jurkka Kuusipalo, Professor, Tampere University of Technology, Paper Converting Technology Publisher Finnish Paper Engineers Association/Paperi ja Puu Oy Paperi ja Puu Oy

2 Table of Contents 1 Introduction Wetting and adhesion Dispersion coating Extrusion coating and products Conventional and novel coating methods Lamination Fibre-based packaging materials Converting of fibre-based packaging materials Converted paper and paperboard as packaging materials Conversion factors Index

3 CHAPTER 1 Introduction 1 Introduction

4 CHAPTER 2 Wetting and adhesion 1 Introduction Theories of adhesion Mechanical interlocking Diffusion theory Electrostatic theory Thermodynamic adsorption theory and surface energy Chemical adhesion Consolidated theory Weak boundary layer theory Work of adhesion vs. failure energy Measuring wetting, adhesion and peel strength Wetting tension solutions Contact angles and surface energy General information for adhesion measurements Peel tests Other tests Industrial and practical applications Paper and paperboard as substrates Adhesion in extrusion coating Adhesion in other applications Surface treatment Flame treatment Corona treatment Plasma treatment Other treatments...49 References

5 CHAPTER 3 Dispersion coating 1 Introduction Polymer dispersions as barrier coatings Application techniques Introduction Blade coaters Rod coaters Air knife coaters Gravure coaters Dip coaters Premetered size press Jet application coaters Spray coaters Curtain coaters Drying and cooling Polymerization and formulation Emulsion polymerization theory Styrene-butadiene Acrylates Other synthetic polymers Biopolymers Polysaccharides Proteins Polyesters and other naturally occurring biodegradable polymers Fillers and additives Nanocomposites

6 Dispersion coating 5 Film formation Basic mechanism Intermolecular forces between colloidal particles Film formation theories Minimum film formation temperature Rheology Rheology of polymer dispersions Base sheet effect on dispersion coating Properties of polymer dispersion films Barrier Water vapour transmission rate Cobb value Gluing, heat sealing, and blocking Grease resistance, odour and taste properties Polymer dispersion-coated products Recycling References

7 CHAPTER 4 Extrusion coating and products 1 Introduction Extrusion coating equipment Hopper, extruder and adapter Extrusion coating die Coextrusion Laminator system Auxiliary equipment Extrusion coating process Principles of extrusion Principles of rheology in extrusion coating Melt flow in a slit die Melt fracture phenomenon in extrusion Critical processing and product properties Rheology related to extrusion coating Odour and taste Pinholes Curling Coefficient of friction Extrusion coating plastics General Polyolefins Polyethylene Polypropylene Copolymers

8 Extrusion coating and products 5.4 Adhesives Adhesives to substrate Interply adhesion in coextrusion Barrier polymers Other polymers Biopolymers Compounds Additives in coating resins Primary antioxidants Secondary antioxidants UV stabilisers Slip agents Substrates and main applications Liquid packaging Other rigid packaging Industrial applications Flexible packaging Photographic papers References

9 CHAPTER 5 Conventional and novel coating methods 1 Introduction Metallising Processes Web materials Product applications Conventional coating methods Wax coating Hot melt coating Lacquer coating Cold seal coating Novel coatings Inorganic coatings Sol-gel coatings Chitosan coatings Deposition Plasma Enhanced Chemical Vapour Deposition (PECVD) Evaporation Sputtering Electron beam Plasma polymerisation References

10 CHAPTER 6 Lamination 1 Introduction Laminating methods Web materials Fibre-based substrates Aluminium foil Plastic films Polyethylene Polypropylene Polyester Polyamides Lactic acid polymers Oriented plastic films Metallised plastic films Net materials Laminating methods Wax and hot melt laminating Extrusion laminating Wet laminating Sodium silicate Casein Starch and dextrin Synthetic latex Dry laminating Solvent-based adhesives Water-based adhesives Solventless laminating

11 Lamination 2.3 Drying Radiation curing Adhesion in laminating Laminated product applications Pressure-sensitive adhesive label laminates General Production of pressure-sensitive adhesive laminate Silicone coating Adhesive coating Lamination Manufacturing of pressure-sensitive adhesive label web Laminate runnability requirements for the label printing machine Printing Die cutting Labelling Functional requirements for pressure-sensitive adhesive labels References

12 CHAPTER 7 Fibre-based packaging materials 1 Introduction Packaging paper Kraft paper Bleached paper Vegetable parchment paper Greaseproof and glassine papers Water-, grease- and oil-resistant papers Waxed paper Specialty treated papers Wet strength papers Tissue papers Coated papers Paperboards Cartonboards Folding boxboard (FBB) White-lined chipboard (WLC) Solid bleached sulphate board (SBS/SBB) Solid unbleached sulphate board (SUS/SUB) Liquid packaging board (LPB) Containerboards Linerboard Corrugating medium Corrugated board manufacturing Introduction Corrugated board grades Production of corrugated board Gluing Quality characteristics of a corrugated sheet Faults in corrugated sheets Die-cutting Printing of corrugated board Requirements for corrugated board set by packaging machines References

13 CHAPTER 8 Converting of fibre-based packaging materials 1 Introduction Package printing Printing methods Adhesion in printing Paperboard converting technologies Varnishing Cutting and creasing Machines and tools Cutting Creasing Embossing Foil blocking Skiving Sealing and gluing General theory of heat sealing Factors affecting heat sealability and seal strength Influence of polymer properties Influence of product manufacturing process Influence of heat sealing process parameters Peelable seals Hot tack Reclosable seals Testing of seal strength Different sealing methods Bar or thermal sealing Ultrasonic sealing Hot gas and flame sealing Gluing Gluing process Adhesion in gluing Gluing of carton structures Fibre-based packages and packaging machines Folding cartons Liquid packaging Flexible packaging References

14 CHAPTER 9 Converted paper and paperboard as packaging materials 1 Introduction Interactions between packaging material, packed foodstuff and environment Permeability of polymers Background Factors affecting permeability Permeability of heterogeneous polymer structures Water vapour barrier Oxygen barrier Grease barrier Aroma barrier Migration Packaging of food products Food shelf life stability Food spoilage mechanisms Microbiological mechanisms Chemical/biochemical mechanisms Physical mechanisms Different food groups and their requirements for packaging materials Ambient foods Chilled foods Frozen foods Packaging techniques improving the safety and quality of foods Modified atmosphere packaging Active and intelligent packaging Testing of food packaging materials Barrier tests

15 Converted paper and paperboard as packaging materials Sealability and hot tack Coefficient of friction Odour and taint Packaging of non-food products Basic requirements for non-food packaging materials Different product groups and their requirements for packaging materials Pharmaceutical packaging Electronics packaging Industrial wrappings Testing of non-food packaging materials Environmental effects of packaging References