Increasing ash without compromise • A comprehensive approach, 2011 PaperCon Conference

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Papermaking fillers are generally much less expensive than fiber. Therefore, by increasing sheet filler content, papermakers can reduce manufacturing costs. During the past decade, the global average filler content for copy paper increased from 15 to 20%; however, further improvements are desired. Historically, trial efforts to significantly increase sheet filler content typically resulted in some combination of lack of sheet bulk and stiffness, inadequate sheet strength, or paper machine runnability problems. Following several years of collaborative research, Ashland Inc. researchers have developed a new technology that is currently being commercialized.

This paper describes this new approach to significantly increase filler content in freesheet grades. The comprehensive approach consists of a novel dry strength additive to improve bonding of carbonate filler particles into the sheet, the modification of the carbonate filler to maintain sheet bulk and stiffness at high filler loading, and the use of an advanced retention/drainage system to maintain paper machine performance as filler content increases.

This paper also reviews commercial trial data from world class paper machines. The data demonstrates that by using this comprehensive approach, sheet filler content can be increased by up to eight percent while maintaining critical sheet quality parameters and paper machine runnability.