Cost Efficient Use of Kaolin Based Filler Pigments, 1999 Papermakers Conference Proceedings

Lester W. House
In this age of the ever changing market conditions governing the paper industry the papermaker must fully utilize installed capital equipment. Larger and faster papermachines can and are making commodity grades of paper more cost efficiently than the older papermachines. The papermaker must find new niche markets for these older machines. The newest printing technologies have presented a unique opportunity for some of these new niche markets, requiring different paper properties.

The freesheet producers keep introducing lighter weight papers. The mechanical pulp paper producers are continually introducing brighter grades that are competing with the freesheet papers. This has led to more paper grade competition. This requires the papermaker to make the best quality sheet at the lowest cost in order to compete in the market place. These changes in the market place have presented the papermaker some unique challenges and opportunities. Using the raw materials that enable the production of valued added products is the key to maximizing capital equipment. The two largest components of the paper matrix, pulp and filler, should be considered first in engineering a paper grade.

The largest portion of the paper matrix is the pulp, and the papermaker must select the correct pulp for the grade. More likely; the pulp available will dictate the grade of paper. The second largest portion of the paper matrix is the filler. The whole pigment supplier industry has been very innovative in the last fifteen years in offering new pigments that offer unique properties.

The kaolin industry has been among the most active in offering unique products: structured kaolin, engineered kaolin, 90 brightness coarse filler kaolin, kaolin based TiO2 replacement pigments, and cationic pigments. The industry also continues to find new applications for the standard kaolin grades. Three examples below demonstrate the cost effective use of kaolin products now available to the papermaker.