|
Harold M. Cody
is Senior Editor
for Pulp & Paper
Magazine
|
Coated paper and paperboard markets have historically been among the most profitable segments of the paper industry. Printers and users pay higher prices for coated grades because it costs more to produce a bright, smooth surface. However, while coated paper/board remains a segment many want to be in, margins will be under increasing pressure in 2001. Cheap imports, excess supply, and weak advertising are the main causes. High energy costs are just the latest problem, with prices driving up mill costs and slashing profits for kaolin producers. With a wave of new capacity coming on line in Europe and the U.S. in the next year, the outlook is troubling.
Raw material use is evolving as mills seek to meet the seemingly conflicting demand for high-quality paper at low cost. The quality-cost squeeze, manifesting itself as an obsession with lowering raw material costs, has also led to a major consolidation of the coating pigment and binder market.
Competitive pressures have instigated developments in paper manufacturing technology that, in turn, are a driver behind changes in the use of pigments, binders, and additives. A key development is the growing importance of large, fast new production lines around the world. The newest lines use all on-machine operations and have annual capacities of 400,000 mtpy or higher. They have made low-cost production a competitive prerequisite and turned coated paper into a true commodity business. While some may argue this point, it defies logic to say a 1,000-mtpd paper machine is making specialty grades. The largest of these are new lines at Haindl in Germany, Burgo in Italy, and Gold East Paper in China. Numerous closures in the U.S. and Canada are due to the inability of these mills to compete on a cost/ton or quality basis with their modern giant counterparts.
Industry consolidation is also resulting in wide ranging changes in coated paper production. Growing international ownership is leading to a major consolidation and restructuring of grade lines and an increase in efforts to differentiate coated paper and board grades. Global producers—such as Stora Enso, UPM-Kymmene, and Sappi—have facilities located around the world and are adjusting their grade lines accordingly to maximize machine efficiency and lower costs. One likely result of this will be a blurring of the traditional differences between European and U.S. coated papers, although this is in the early stages of development.
SPECIALTY PIGMENT AND CARBONATE USE. To meet all of these challenges, the products used to make coated paper and paperboard are changing. Mills are using engineered clays and specialty pigments to cut use of expensive opacifying pigments such as titanium dioxide. The drive to higher brightness at lower cost has led to the growing use of ground calcium carbonate in paper coatings. Average ash levels are also increasing as higher cost fiber is replaced by minerals, further boosting pigment use. Faster machines present a major challenge to coating formulators. Higher speeds mean higher shear forces, which necessitate adjustments to coating color makeup. The use of modified particle size distribution pigments and single binder systems is growing as a result. Increased carbonate use has hurt demand for kaolin. However, kaolin use will continue to constitute a large portion of coating pigment demand. The use of precipitated carbonate in coating remains small.
Coating technology is changing as well. Use of size press or film roll coating as a primary coat or as a pre-coat is also growing. For coated free-sheet, the use of multiple coatings, which more commonly occurs in Europe, is increasing in North America. Multiple coating is contributing to rising carbonate use and higher ash levels. Carbonate and engineered kaolin use are also benefiting from growing size press pigment application, as evidenced by the fact that pigments designed for size press applications are now on the market.
A register of coating pigments, binders, and additives is provided below.
|
Tradename
|
Description
|
Brightness
|
Particle Size1
|
Shipping Form
|
|
DOW EMULSION POLYMERS www.dow.com.
|
|
(circle No. 501 on Reader Service Card)
|
|
PB 6656A
|
Solid plastic pigment
|
NA
|
0.222
|
Bulk/tote/drum
|
|
PB 6688A
|
Solid plastic pigment
|
NA
|
0.13
|
Bulk/tote/drum
|
|
722HS
|
Solid plastic pigment
|
NA
|
0.45
|
Bulk/tote/drum
|
|
755A
|
Solid plastic pigment
|
NA
|
0.22
|
Bulk/tote/drum
|
|
756A
|
Solid plastic pigment
|
NA
|
0.22
|
Bulk/tote/drum
|
|
788A
|
Solid plastic pigment
|
NA
|
0.13
|
Bulk/tote/drum
|
|
HS 2000NA
|
Hollow sphere plastic pigment
|
NA
|
0.80
|
Bulk/tote/drum
|
|
HS 3000NA
|
Hollow sphere plastic pigment
|
NA
|
1.0
|
Bulk/tote/drum
|
|
ENGELHARD CORP. www.engelhard.com
|
|
(circle No. 502 on Reader Service Card)
|
|
KAOLIN
|
|
GLOSSING GRADES
|
|
Miragloss 91
|
Ultra-fine psd, premium brightness
|
91.0 min
|
86-963
|
Dry, 71% solids
|
|
Miragloss OP
|
Optimized for high print gloss and coverage
|
90.0 min
|
88-94
|
Dry, 70% solids
|
|
Miragloss
|
Fine psd, standard brightness
|
87.5-89.0
|
88-924
|
Dry, 70% solids
|
|
Ultra Gloss 90
|
Superior high shear viscosity
|
90.0 min
|
90-95
|
Dry, 70% solids
|
|
COATING GRADES
|
|
Ultra White 90
|
Premium brightness, No. 1 hydrous
|
90.0 min
|
90-94
|
Dry, 70% solids
|
|
Lustra
|
Standard brightness, No. 1 hydrous
|
86.5-88.0
|
90-94
|
Dry, 70% solids
|
|
Ultra Cote
|
Premium brightness, No. 2 hydrous
|
90.0 min
|
78-84
|
Dry, 70% solids
|
|
HT
|
Standard brightness, No. 2 hydrous
|
85.5 min
|
78-84
|
Dry, 70% solids
|
|
DELAMINATED GRADES
|
|
Nuclay
|
Standard brightness for coating
|
87.5-89.0
|
78-82
|
Dry, 68% solids
|
|
Nufil
|
Standard brightness for filling
|
87.5-89.0
|
78-82
|
Dry, 68% solids
|
|
Nufil 90
|
Premium brightness for filling
|
89.0-90.5
|
72-80
|
Dry, 68% solids
|
|
Nugloss
|
High brightness for coating
|
87.5-89.5
|
82-86
|
Dry, 68% solids
|
|
SPECIALTY GRADES
|
|
Miraclipse PG
|
Premium brightness, engineered psd
|
90.0 min
|
89-92
|
Dry, 68% solids
|
|
Exsilon
|
High performance, structured psd
|
86.5 min
|
NA
|
63% solids
|
|
Eclipse 650
|
High performance, engineered psd
|
86.5-88.0
|
86-90
|
Dry, 70% solids
|
|
Luminex
|
Ultra-high brightness calcined
|
95.8-96.5
|
80-90
|
Dry
|
|
INKJET GRADES
|
|
Digitex
|
Premium brightness for Inkjet
|
91.5-92.5
|
NA
|
Dry
|
|
Digitex 1000
|
Ultra-high brightness for Inkjet
|
94.5-95.0
|
NA
|
Dry
|
|
METERING SIZE PRESS GRADES
|
|
Mirafilm 500
|
Premium brightness, superior runnability
|
89.0-90.0
|
84.0-88.0
|
Dry, 66% solids
|
|
Mirafilm 600
|
Premium brightness, superior opacity
|
90.0 min
|
89.0-92.0
|
Dry, 68% solids
|
|
Calcined Grades
|
|
Ansilex 93
|
High brightness calcined
|
92.5-93.5
|
86-90
|
Dry
|
|
Ansilex
|
Standard brightness calcined
|
90.0-92.5
|
86-90
|
Dry, 51% solids
|
|
Excaliber
|
Standard brightness, high opacity
|
80.0-82.0
|
86-92
|
Dry
|
|
FILLER GRADES
|
|
KWW
|
Standard hydrous slurry filler
|
83.0-85.0
|
45-65
|
Dry, 70% solids
|
|
MCS
|
Standard hydrous dry filler
|
83.5-85.0
|
45-55
|
Dry
|
|
Note: psd=particle size distribution
|
|
HUBER ENGINEERED MATERIALS www.huber.com
|
|
(circle No. 503 on Reader Service Card)
|
|
HIGH GLOSSING CLAYS
|
|
Hydragloss 92
|
Ultra high bright, blue white
|
92.0-92.5
|
98-100
|
Spray dried, slurry
|
|
Covergloss
|
Engineered, high performance
|
90.0-91.0
|
96-99
|
Spray dried, slurry
|
|
Hydralux 91
|
High bright, ultra blue white
|
90.5-92.5
|
96-100
|
Spray dried, slurry
|
|
Hubergloss 2000
|
High bright, glossing
|
90.0-91.5
|
92-98
|
Spray dried, slurry
|
|
Hubergloss
|
High bright, glossing
|
90.0-92.0
|
93-97
|
Spray dried, slurry
|
|
Hydragloss 90
|
High glossing, blue white
|
90.0-91.5
|
96-100
|
Spray dried, slurry
|
|
Hydragloss
|
High glossing, standard brightness
|
87.0-88.5
|
92-98
|
Spray dried, slurry
|
|
Hydraglaze
|
High glossing, standard brightness
|
86.5-88.5
|
94-98
|
Spray dried, slurry
|
|
Hydrafine 90
|
No.1 high glossing, high brightness
|
90.0-91.5
|
90-96
|
Spray dried, slurry
|
|
Hydracote A
|
No.1 high glossing, high brightness
|
90.0-92.0
|
90-94
|
Spray dried, slurry
|
|
STRUCTURED CLAYS
|
|
Hycal
|
Calcined
|
92.0-94.0
|
86-96
|
Dry
|
|
Hubertex
|
Calcined
|
92.0-93.5
|
NA
|
Dry, slurry
|
|
Hubertex D
|
Calcined, high solids slurry
|
92.0-93.0
|
NA
|
Slurry
|
|
Sampaque 5002
|
Structured, Low abrasion
|
91.0-93.0
|
85-95
|
Dry
|
|
SPECIAL PURPOSE CLAYS
|
|
Lithoprint
|
High bright, High print gloss
|
89.5-91.0
|
88-92
|
Spray dried, Slurry
|
|
Huber BC
|
TiO2 reduction in paperboard coatings
|
90.0-92.0
|
NA
|
Slurry
|
|
Hydramatte
|
Coarse delaminated
|
87.5-89.0
|
NA
|
Spray dried, Slurry
|
|
Fiberex
|
Economical extender-linerboard
|
68.0-73.0
|
NA
|
Slurry
|
|
Huber PK-102
|
Chemically modified-pitch control
|
74.0-76.0
|
80-85
|
Dry
|
|
MULTI-PURPOSE CLAYS
|
|
Hydrasperse 90
|
High bright No.2
|
89.5-91.0
|
80-86
|
Spray Dried, Slurry
|
|
Hydracote B
|
High bright No.2
|
89.5-92.0
|
80-86
|
Spray Dried, Slurry
|
|
Hydrasperse
|
Standard brightness No.2
|
86.0-87.5
|
80-86
|
Spray Dried, Slurry
|
|
Hydrafine
|
Standard brightness No.1
|
87.0-88.5
|
90-96
|
Spray Dried, Slurry
|
|
Hydrafil 90
|
High bright, delaminated, filler
|
89.0-90.0
|
NA
|
Spray Dried, Slurry
|
|
Huberfil 90
|
High bright, delaminated, filler
|
89.5-91
|
82-90
|
Slurry
|
|
Hydrafil
|
Standard bright, delam, filler
|
86.5-88.0
|
NA
|
Spray Dried, Slurry
|
|
Hydraprint
|
Standard delaminated
|
87.5-89.0
|
NA
|
Spray Dried, Slurry
|
|
Hydraplate
|
Standard delaminated
|
87.5-89.5
|
80-88
|
Spray Dried, Slurry
|
|
Hydraplate LV
|
Standard delaminated
|
87.5-89-5
|
80-88
|
Spray Dried, Slurry
|
|
PRECIPITATED SILICATES AND SILICAS5
|
|
Hydrex P
|
Ultra high bright silicate
|
98.0-100
|
5-8
|
Dry
|
|
Huberfil 96
|
High bright silicate
|
91.0-93.0
|
4-10
|
Slurry
|
|
Zeosyl 200
|
Ultra high bright silica
|
98-100
|
1-4
|
Dry
|
|
Optisil 3265
|
Ink jet coating silica
|
98-100
|
1-4
|
Dry
|
|
ALUMINA TRIHYDRATE
|
|
Hydrad 15
|
Fine particle, high bright
|
94-96
|
70-80
|
Slurry
|
|
Hydrad C
|
Medium particle, high bright
|
96
|
47
|
Dry
|
|
Hydrad F
|
Coarse particle, high bright
|
94
|
29
|
Dry
|
|
PRECIPITATED CALCIUM CARBONATE6
|
|
Hubercarb Scalenohedral (S-PCC) Filler
|
96-98
|
1.6-3.0
|
Slurry
|
|
Hubercarb Rhombohedral (R-PCC) Filler
|
96-98
|
1.4-2.4
|
Slurry
|
|
Hubercarb Coating PCC (S & R PCC)
|
96-98
|
0.4-3.0
|
Slurry
|
|
COMPOSITE PIGMENT6
|
|
Hubercom
|
High bright, print through control, Particle
|
96*
|
2.5
|
Slurry
|
|
Notes: Clays, ATH - Particle size distribution, %finer than 2µ based on Sedigraph method. Precipitated Silicates and Silicas - particle size µ based on Horiba method. PCC, Composite Pigment – median particle size based on Sedigraph method *Hubercom-ISO brightness
|
|
IMERYS (N. America) www.imerys-paper.com.
|
|
(circle No. 504 on Reader Service Card)
|
|
KAOLIN
|
|
FUNCTIONAL
|
|
Astra-Jet
|
Functional
|
90
|
88
|
56% solids
|
|
ENGINEERED
|
|
Astra-Plus
|
Fine engineered
|
90
|
97
|
64.5% solids, dry
|
|
Alpha-Print 100
|
Fine engineered
|
90.5
|
94
|
70% solids, dry
|
|
Capim DG
|
Fine engineered
|
90.5
|
92
|
71% solids,
|
|
Countour 100
|
Delaminated
|
88
|
90
|
67% solids, dry
|
|
COATING HIGH BRIGHTNESS
|
|
Astra-Sheen
|
Premium ultrafine No. 1
|
90.5
|
99
|
70.5% solids, dry
|
|
Astra-Gloss
|
Fine No. 1
|
90
|
95
|
70% solids, dry
|
|
Astra-Cote
|
No. 1
|
90
|
92
|
70% solids, dry
|
|
Beta-Brite
|
No. 2
|
90
|
83
|
70% solids, dry
|
|
Capim NP
|
Delaminated
|
90.5
|
80
|
67% solids
|
|
Capim CC
|
Delaminated
|
89
|
50
|
70% solids
|
|
COATING REGULAR BRIGHTNESS
|
|
Astra-Glaze
|
Fine No. 1
|
88
|
96
|
70% solids, dry
|
|
Premier
|
No. 1
|
88
|
92
|
70% solids, dry
|
|
KCS
|
No. 2
|
87
|
83
|
70% solids, dry
|
|
DELAMINATED
|
|
Astra-Plate
|
Delaminated
|
88
|
84
|
67.5% solids, dry
|
|
CALCINED
|
|
Alphatex
|
Calcined
|
92.5
|
93
|
50% solids, dry
|
|
Alphatex HP
|
Calcined
|
92
|
91
|
50% solids, dry
|
|
Opacitex
|
Calcined
|
80
|
88
|
Dry
|
|
Deltatex
|
Calcined
|
92.5
|
92
|
59% solids, dry
|
|
Liner-fil 300
|
Calcined
|
92.5
|
91
|
50% solids, dry
|
|
Astra-Plex
|
Calcined composite
|
56% solids
|
|
GROUND CALCIUM CARBONATE
|
|
Carbilux
|
Coating
|
96
|
97
|
75% solids
|
|
Carbital 95
|
Coating
|
96
|
93
|
75% solids
|
|
Carbital 90
|
Coating
|
97
|
90
|
75% solids
|
|
Carbital 75
|
Coating/filling
|
97
|
75
|
75% solids
|
|
Carbital 60
|
Coating/filling
|
97
|
60
|
75% solids, dry
|
|
Carbital 35
|
Coating/filling
|
96
|
35
|
75% solids, dry
|
|
PRECIPITATED CALCIUM CARBONATE
|
|
Opti-Cal Print
|
Rhombohedral, coating
|
95-98
|
0.5-0.7 1
|
72% solids
|
|
Opti-Cal Matte
|
Rhombohedral, coating
|
95-98
|
2.0-2.2 1
|
72% solids
|
|
Opti-Cal Gloss
|
Aragonite, coating
|
95-98
|
0.3-0.5 1
|
72% solids
|
|
OMNOVA Solutions Inc. and ROHM and HAAS Company www.omnova.com/www.rohmhaas.com
|
|
(circle No. 505 on Reader Service Card)
|
|
ROPAQUE
|
|
HP-1055
|
Hollow sphere synthetic pigment
|
99
|
1.0
|
Bulk
|
|
AF-1055
|
Hollow sphere synthetic pigment
|
99
|
1.0
|
Bulk
|
|
BC-643
|
Hollow sphere synthetic pigment
|
99
|
0.6
|
Bulk
|
|
HP-543P
|
Hollow sphere synthetic pigment
|
99
|
0.5
|
Bulk
|
|
OP-84
|
Hollow sphere synthetic pigment
|
99
|
0.4
|
Bulk
|
|
OMYA, Inc. www.omya-NA.com
|
|
(circle No. 506 on Reader Service Card)
|
|
CALCIUM CARBONATE COATING PRODUCTS
|
|
Hydrocarb PG-3
|
Blade cleaning, runnability
|
94-96
|
35
|
Slurry, dry
|
|
Hydrocarb 60
|
Pre-coats, matte grades
|
95-97
|
60
|
Slurry, dry
|
|
Hydrocarb 90
|
Multi-application pigment
|
95-97
|
90
|
Slurry, dry
|
|
Hydrocarb HG
|
High gloss
|
92.5-94.5
|
99
|
Slurry
|
|
Covercarb HP
|
Coverage, opacity
|
95-97
|
96
|
Slurry
|
|
Covercarb 85
|
Coverage, gloss, opacity
|
95-97
|
98
|
Slurry
|
|
SPECIALTY MINERALS, Inc. www.mineralstech.com
|
|
(circle No. 507 on Reader Service Card)
|
|
CALCIUM CARBONATE4
|
|
Albaglos S
|
Coating grade PCC
|
97
|
0.55
|
71% solids slurry
|
|
Albaglos
|
Coating grade PCC
|
97
|
0.8
|
71% solids slurry
|
|
Albaglos L
|
Coating grade PCC
|
96
|
1.5
|
71% solids slurry
|
|
Albaglos XL
|
Coating grade PCC
|
96
|
2.2
|
71% solids slurry
|
|
Opacarb A40
|
Coating grade PCC
|
97
|
0.4
|
71% solids slurry
|
|
Opacarb A50
|
Coating grade PCC
|
97
|
0.5
|
71% solids slurry
|
|
Opacarb A60
|
Coating grade PCC
|
97
|
0.6
|
71% solids slurry
|
|
1. percent less than 2 microns unless specified, 2. mean particle size microns, 3. less than 0.5 micron, 4. less than 1.0 micron, 5. particle size, microns, 6. median particle size, microns.
|
|
BINDERS
|
|
Product
|
Key Benefits
|
Applications
|
|
DOW EMULSION POLYMERS www.dow.com
|
|
(circle No. 508 on Reader Service Card)
|
|
STYRENE BUTADIENE LATEX BINDERS
|
|
COATED PRINTING PAPERS
|
|
CP 615NA
|
Delta gloss (snap), low paper gloss, binding strength, runnability, colloidal stability
|
fp, sp
|
|
CP 617NA
|
Print and paper gloss, thermal finishing
|
fp
|
|
CP 620NA
|
Balance of binding strength/paper gloss, natural binder compatibility
|
fp, cgw, sp
|
|
CP 638NA
|
Runnability and binding strength, colloidal stability
|
fp, cgw, sp
|
|
CP 651NA
|
Print gloss, print mottle resistance, binding strength
|
fp
|
|
CP 655NA
|
Paper stiffness (rattle), print gloss
|
fp, cgw
|
|
CP 657NA
|
Rotogravure printability and runnability
|
cgw
|
|
CP 658NA
|
Dual offset/roto printability, binding strength
|
fp, cgw, sp
|
|
CP 692NA
|
Binding strength, runnability
|
fp, cgw, sp
|
|
COATED PAPERBOARD
|
|
CT 5000NA
|
Fiber coverage, water retention, and glueability and ink receptivity
|
sbs, cuk, rpb
|
|
PB 6620NA
|
Balance of binding strength/paper gloss, natural binder compatibility
|
sbs, cuk , rpb
|
|
PB 6638NA
|
Ink and varnish gloss, binding and runnability, colloidal stability
|
sbs, cuk, rpb
|
|
PB 6681NA
|
Paper gloss, glueability
|
sbs, cuk, rpb
|
|
PB 6692NA
|
Binding strength, runnability
|
sbs, cuk, rpb
|
|
FILM COATING
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FC 1020
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Misting and orange peel, mech. stability, binding strength, print gloss, print mottle resistance
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fp, cgw
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FC 1030
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Misting and orange peel, mech. stability, binding strength, low sheet gloss
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fp, cgw
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FC 1040
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Misting and orange peel, mech. stability, paper gloss, thermal finishing
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fp, cgw
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FC 1050
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Misting and orange peel, mech. stability, binding strength
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fp, cgw
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FC 1060
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Misting and orange peel, mech. stability, paper stiffness (rattle), print gloss
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fp, cgw
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STYRENE ACYRLIC LATEXES
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PB 6820NA
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Paper/print gloss, natural binder compatibility, heat/light stability, low odor
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sbs, cuk, rpb
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RAP 800NA
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Balance of binding strength/paper gloss, runnability, heat/light stability, low odor
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sbs, cuk, rpb
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RAP 810NA
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Print mottle resistance, paper stiffness (rattle), heat/light stability, low odor
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sbs, cuk, rpb
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CP 6800NA
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Balance of paper strength/binding, gloss, runnability, heat/light stability, low odor
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fp, sp
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CP 6810NA
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Print mottle resistance, paper stiffness (rattle), heat/light stability, low odor
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fp, sp
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Key: fp = fine paper, cgw = coated groundwood, sp = specialty paper, sbs = solid bleached sulfate, cuk = coated unbleached kraft, rpb = recycled paperboard.
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COATING ADDITIVES
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Product
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Key Benefits
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Applications
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DOW EMULSION POLYMERS www.dow.com
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(circle No. 509 on Reader Service Card)
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RHEOLOGY MODIFIERS
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Ucar Polyphobe 205
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Low high-shear viscosity, low molecular weight
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fp, cgw
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Ucar Polyphobe 206
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High low-shear viscosity, high molecular weight, efficiency
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fp, cgw
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Tradename
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Benefit/Chemistry
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Application
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EKA CHEMICALS Inc. www.ekachem.com
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(circle No. 510 on Reader Service Card)
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DEFOAMERS
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D-Foam 9073C
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Non-silicone synthetic organic
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Stable, will not cause fish eye, for water-borne polymer systems
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D-Foam 9074
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Non-silicone
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Stable, oil-based, for coating and size press
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RHEOLOGY MODIFIERS
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Viscote 9052
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Anionic acrylic emulsion polymer
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Builds viscosity, increases water retention
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Viscote 9054
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Anionic synthetic polymer
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Imparts low-shear viscosity, water retention
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OPTICAL BRIGHTENERS
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O-Brite 7020
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Tetrasulfonated stilbene
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Internal or surface treatment
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O-Brite 7025
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Hexasulfonated stilbene
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Optimum brightness, alkaline or acid papers
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INSOLUBILIZERS
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Azcote 5800M
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Ammonium zirconium carbonate
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Reduces print blanket dust, for coated board/all synthetic binder systems
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Kzcote 5000
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Potassium zirconium carbonate
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No ammonia
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Curez 5550
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Modified ethanedial oxalaldehyde
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Starch insolubilizer, eliminates roll blocking in silicone release grades
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Curez 5650
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Modified glyoxal resin
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Lightweight coated papers
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Melrez 5300
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Melamine formaldehyde resin
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Low free formaldehyde resin, water resistance, insolublizes at low pH
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Melrez 5350
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Methylated amino resin
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Water resistance, insolubilizes at low pH
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Melrez 5480
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Methylated melamine resin
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Wet strength, surface treatment applications such as label
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LUBRICANTS
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Bladecote 95
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100% active liquid
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Reduces scratches, streaks, for high-shear blade coating
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Gloscote 50
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Calcium stearate dispersion
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Stable in long term storage
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Dualcote 50
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Co-emulsion polyethylene/calcium stearate
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Single lubricant use
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Polycote 30
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Polyethylene emulsion
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Stable emulsion, used with wide variety of additives
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Polycote 60
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High solids modified polyethylene emulsion
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High-shear stability
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