DITP 41st International Symposium Bled, November 19 – 20, 2014

Alternative Pigment Concepts for New Market Requirements in Board Application

Georg Häusler Technical Services & Innovation Forest Products Industry

Omya International AG, Switzerland

This document contains proprietary information which shall not be

used and disclosed without Omya explicit written authorization.

DITP 41st International Symposium Bled, November 19 – 20, 2014 2

Content

Major trends in the paper & board market

Different Case Studies

Coverage and brightness improvements

Faster ink setting in Flexographic printing

High glossability – glossy paper and matte calendering

Summary

This document contains proprietary information which shall not be

used and disclosed without Omya explicit written authorization.

DITP 41st International Symposium Bled, November 19 – 20, 2014 3

Global Market Size and Growth of Selected Industries 2012

0

250

500

750

1000

Smartphones Graphic Paper Packaging

US

D b

illi

on

CAGR 14.5 % CAGR 0 %

CAGR 5 %

This document contains proprietary information which shall not be

used and disclosed without Omya explicit written authorization.

DITP 41st International Symposium Bled, November 19 – 20, 2014 4

Long-Term Growth of Paper & Board Through 2025

Source: Poyry World Paper Markets up to 2025_2

This document contains proprietary information which shall not be

used and disclosed without Omya explicit written authorization.

DITP 41st International Symposium Bled, November 19 – 20, 2014 5

Germany; FFB Market – Volume Production & Sales

Source: FFI Jahresbericht 2013

Sales in Mio. EUR

Production volume in 1000to

This document contains proprietary information which shall not be

used and disclosed without Omya explicit written authorization.

DITP 41st International Symposium Bled, November 19 – 20, 2014 6

Numbers of FBB Producers

Source: FFI Jahresbericht 2013

This document contains proprietary information which shall not be

used and disclosed without Omya explicit written authorization.

DITP 41st International Symposium Bled, November 19 – 20, 2014 7

Coverage and Brightness Objectives Omyaprime® HO 40

Coverage / hiding power / brightness development

Replacement of clay

A homogeneous surface for improved printability

This document contains proprietary information which shall not be

used and disclosed without Omya explicit written authorization.

DITP 41st International Symposium Bled, November 19 – 20, 2014 8

Coverage and Brightness Omyaprime® HO 40

Omyaprime® HO 40

Aragonite PCC

Specific surface area = 14.0 m²/g

Average particle diameter (d50) = 0.42 µm

Features:

High gloss, high opacity, good coverage,

moderate rheology

Application(s):

Topcoat wood-free, Board, LWC

This document contains proprietary information which shall not be

used and disclosed without Omya explicit written authorization.

DITP 41st International Symposium Bled, November 19 – 20, 2014 9

Board quality: recycled based Folding Box Board

280 g/m² (GD2 Quality)

Triple Coated Board – Pre- and Topcoat constant

Middle Coat: Standard 1:1 replaced by

GCC / Clay blend : Omyaprime® HO 40

Coater Speed: 550 m/min

Coat weight 14 g/m²

Coverage and Brightness / Trial Setup

This document contains proprietary information which shall not be

used and disclosed without Omya explicit written authorization.

DITP 41st International Symposium Bled, November 19 – 20, 2014 10

Omyaprime® HO 40

Control Brightness -UV [%]

Print Gloss

[%]

Roughness PPS [µm]

Wet Pick [m/s]

Inko 2 2.5

3.0

3.5

4.0

1 2 3 4

78

80

82

84

73

75

77

79

66

68

70

72

86 84 82 80

4

3

2

1

46

44

42

40

Varnish Gloss

[%]

Board Gloss

[%]

Brightness +UV [%]

Dry Pick [m/s]

Inko 2

Coverage and Brightness / Results Mill Trial

This document contains proprietary information which shall not be

used and disclosed without Omya explicit written authorization.

DITP 41st International Symposium Bled, November 19 – 20, 2014 11

Coverage and Brightness – Omyaprime® HO 40 - Summary

Compared to Standard:

Improved coverage and hiding power

Enhanced brightness development

Topped surface and print properties – less mottling

Increased cost recovery

This document contains proprietary information which shall not be

used and disclosed without Omya explicit written authorization.

DITP 41st International Symposium Bled, November 19 – 20, 2014 12

Fast Flexographic Printability Objective Omyaprime® HA 12

Homogeneous surface and good flexographic printability

No smearing between print units without intermediate drying process

This document contains proprietary information which shall not be

used and disclosed without Omya explicit written authorization.

DITP 41st International Symposium Bled, November 19 – 20, 2014 13

Fast Flexographic Printability – Omyaprime® HA 12

Omyaprime® HA 12

Rhombohedral PCC

Specific surface area = 21.0 m²/g

Average particle diameter (d50) = 0.21 µm

Features:

Fast ink-setting, high gloss

Application(s):

Topcoat board

This document contains proprietary information which shall not be

used and disclosed without Omya explicit written authorization.

DITP 41st International Symposium Bled, November 19 – 20, 2014 14

Fast Flexographic Printability – Generic Information

Flexography Offset

Ink system Water or solvent

based, pure ink

Oil based ink-water

emulsion

Ink viscosity Very low Very high

Ink transfer

Via Anilox roll to

raised-image flexible

and soft polymer

printing plates.

Via ink rollers to

hydrophobic parts on

flat aluminum plate to

rubber blanket.

Available lab

methods

Few options, e.g.

Saueressig

Robust methods like

IGT or Prüfbau

Flexography

Offset

This document contains proprietary information which shall not be

used and disclosed without Omya explicit written authorization.

DITP 41st International Symposium Bled, November 19 – 20, 2014 15

Fast Flexographic Printability – Trial Setup

Board Quality: recycled based Folding Box Board

210 g/m² (GD2 Quality)

Triple Coated Board – Pre- and Middle Coat constant

Top Coat: Standard 1:1 replaced by

ultrafine GCC : Omyaprime® HA 12

Coater Speed: 800 m/min

Coat weight 7 g/m²

This document contains proprietary information which shall not be

used and disclosed without Omya explicit written authorization.

DITP 41st International Symposium Bled, November 19 – 20, 2014 16

Brightness -UV [%]

Print Gloss

[%]

1.4

1.6

1.8

2

1.4 1.6 1.8 2

80

82

84

86

73

75

77

79

66

68

70

72

56 54 52 50

2

1.8

1.6

1.4

2

1.8

1.6

1.4

Board Gloss

[%]

Brightness +UV [%]

Black

Ink density

Yellow

Ink density

Mangenta

Ink density

Cyan

Ink density

Fast Flexographic Printability – Results Mill Trial

Omyaprime® HA 12

Control

This document contains proprietary information which shall not be

used and disclosed without Omya explicit written authorization.

DITP 41st International Symposium Bled, November 19 – 20, 2014 17

Fast Flexographic Printability – Omyaprime® HA 12 Summary

Compared to Standard:

Improved surface and print properties

Higher color densities in half and full tone areas

No smearing and trapping

Print unit increased the speed by 20%

This document contains proprietary information which shall not be

used and disclosed without Omya explicit written authorization.

DITP 41st International Symposium Bled, November 19 – 20, 2014 18

High Gloss Performance – Objective – Omyaprime® HG 30

High glossability without the use of a supercalender

Gloss target with matte calender (machine calender) higher than 50° (Tappi 75°)

This document contains proprietary information which shall not be

used and disclosed without Omya explicit written authorization.

DITP 41st International Symposium Bled, November 19 – 20, 2014 19

High Gloss Performance – Omyaprime® HG 30

Omyaprime® HG 30

GCC/PCC Co-processing

Specific surface area = 23.0 m²/g

Average particle diameter (d50) = 0.27 µm

Features:

High gloss, premium printability, very

good runnability

Application(s):

Topcoat wood-free

This document contains proprietary information which shall not be

used and disclosed without Omya explicit written authorization.

DITP 41st International Symposium Bled, November 19 – 20, 2014 20

High Gloss Performance – Trial Setup

Paper quality: double coated wood-free 135 g/m²

(offset quality)

Double coated paper – precoat constant

Topcoat: Standard 1:1 replaced by

ultrafine GCC : Omyaprime® HG 30

Coater Speed: 1200 m/min

Coat weight 12 g/m²

This document contains proprietary information which shall not be

used and disclosed without Omya explicit written authorization.

DITP 41st International Symposium Bled, November 19 – 20, 2014 21

Brightness -UV [%]

Print Gloss

[%]

68

70

72

74

1 2 3 4

80

82

84

86

85

86

87

88

48

50

52

54

54 52 50 48

19

18

17

16

2

1.9

1.8

1.7

Paper Gloss

[%]

Brightness +UV [%]

PPS

[µm]

Burn Out

Papeye

Noir

Porometrique

Dry pick Inko 2

[m/sec]

High Gloss Performance – Results of Mill Trials

Omyaprime® HG 30

Control

This document contains proprietary information which shall not be

used and disclosed without Omya explicit written authorization.

DITP 41st International Symposium Bled, November 19 – 20, 2014 22

High Gloss Performance – Omyaprime® HG 30 - Summary

Compared to Standard:

Improved surface and print properties

Gloss target achieved without additional calendering

This document contains proprietary information which shall not be

used and disclosed without Omya explicit written authorization.

DITP 41st International Symposium Bled, November 19 – 20, 2014 23

Summary

Omyaprime® HA 12

Rhombohedral PCC

Specific surface area = 21.0 m²/g

Average particle diameter (d50) = 0.21 µm

Omyaprime® HG 30

GCC / PCC Co-processing

Specific surface area = 23.0 m²/g

Average particle diameter (d50) = 0.27 µm

Omyaprime® HO 40

Aragonite PCC

Specific surface area = 14.0 m²/g

Average particle diameter (d50) = 0.42 µm

This document contains proprietary information which shall not be

used and disclosed without Omya explicit written authorization.

DITP 41st International Symposium Bled, November 19 – 20, 2014 24

Do You Have

Any Questions