Omya Calcium Carbonate is Pushing Boundaries in Packaging Board - Paper Technology International 2023 - Paper Technology International 2023 - Flipbook - Page 80

Omya Calcium Carbonate is Pushing Boundaries in Packaging Board - Paper Technology International 2023

PAPERTECHNOLOGYINTERNATIONAL
Omya Calcium Carbonate is Pushing Boundaries in Packaging Board - Paper Technology International 2023
During the mid-2010s Omya began to look closer at
containerboard, specifically testliner grades. The vast majority of
this linerboard in most of the world is made out of recycled fibers,
mostly old corrugated containers (OCC). In recent years the industry
landscape experienced significant growth with new machine
capacities by either green field projects, upgrading existing assets,
or conversion from Graphic Paper machines. This growth resulted in
greater awareness of recycled fibers as a precious raw material.
In 2015 Omya introduced a concept utilizing specific
mineral fillers in the containerboard production process. With an
initial focus on boosting board machine output, this concept has
convinced a significant number of containerboard mills to begin
using Omyaboard mineral fillers. Omyaboard grades improve the
de-watering performance in the wet-end section of the machine. By
having the same specific energy intake in the drying section, the
machine output can be increased significantly. Based on experience
as the rule of thumb 1% Omyaboard brings a 1% output increase or
a 1% reduction in energy demand for drying.
This concept is not only limited to increased output. In cases
machine speed is already maxed due to increased drive train or
other mechanical reasons, implementing Omyaboard also allows
reduced drying energy demand per tonne of paper produced. In
these times of especially volatile energy prices, when for example
Natural Gas EU Dutch TTF Spot (EUR/MWh) is almost four times
higher in August 2022 compared with the beginning of this year.
Similar strains are seen in the North American industry as the
Natural Gas Spot Price Henry Hub (USD/million BTU) spiked in
August almost 2.5 higher than in January 2022. Unused portions of
available energy capacity can be utilized for other purposes when
applying the Omyaboard concept in the scope of energy savings.
Selling off overcapacity into the grid is an attractive option too.
The secondary ash content of incoming recycled fibers is
a parameter that impacts the relevant mechanical properties of
testliner grades, such as SCT (Short Compression Test) or Burst
Strength. Fiber quality will always vary in each geographic region
but the fiber mix will vary as well. In a specific case where the
secondary ash level was 16%, when substituting recycled fibers
with Omyaboard at 2% mechanical properties of the testliner were
not degraded. Implementing this mineral filler concept could also
support the quality consistency in containerboard grades. There are
even ideal cases where an integrated ash level sensor measuring
secondary ash level can trigger the appropriate dosage rate of such
filler by targeting a constant ash level of the final linerboard.
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Every case is unique because of the paper machine
configuration, range of linerboard grades produced, available fibers,
and other aspects. By starting with a comprehensive wet-end
analysis covering various factors, Omya specialists will develop a
proposal for the best-fitting Omyaboard product and can guide you
through implementing this concept in your production.
The attractiveness of recycled paper and board as a
fiber source is only possible because of the reliable and proven
infrastructure to collect and process this resource in many countries.
However, structural changes in
the paper market, specifically with
the demand for graphic paper, are
severally affecting the available
volume of high-quality fibers which
feed the recycled fiber streams.
Stakeholders in the industry are
continuing to report concerns
about skyrocketing prices for white
shaving or other adequate fibers.
Besides the price, the availability of
required volumes is even becoming
a challenge. The future of white fiber
availability doesn’t seem likely to
change, so what if there was a way
to circumvent a dependency on white
fibers?

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