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Cham Paper Group
Mark Gooseman
Cham Paper Group (UK) LtdRoyal Victoria HouseTunbridge WellsKent TN2 [email protected]
PaperSpeciality or Commodityand the New Challenges
An overview of the Market(As a papermaker‘s view).
Mark R Gooseman
Cham Paper Group
• Introduction to Cham Paper Group
• Are Metallising papers a commodity?
• Base Papers for metallising – what is the difference?
• Market segments of metallised papers and their technical requirements
• Future demands for metallising base papers
• Risk for metallising base papers
Overview
Cham
The Cham Paper Group
Tenero
Hunsfos
Condino
Carmignano
Flexible Packaging & TechnicalPapers
Pressure Sensitive Base Papers
Technical Paper Grades
Sales 2004 – tonnesProduct Range
Other Papers
13%
Flexible
Packaging
24%
Pressure
Sensitive
30%
Technical
Grades
33%
Sales 2004 – tonnes: % per region
Italy
10%
Germany
24%
United Kingdom
10%
France
3%
Netherlands
10%
Asia
8%Rest World
3%
Switzerland
2%
Spain
7%
Norway
1%
Rest Europe
7%
North/-South
America
11%
Belgium
4%
SummarySummary
uu 265 000 265 000 tonnes capacity fromtonnes capacity from HiHi--TechTech. . machinesmachines
uu 8 Paper Machines (MF and MG)8 Paper Machines (MF and MG)
uu 4 Off4 Off--line line Coaters Coaters
uu 2 On2 On--line line CoatersCoaters
uu SupercalendersSupercalenders, , MachineMachine calenderscalenders, , WindersWinders//SlittersSlitters
uu CoatedCoated and and uncoated Specialtyuncoated Specialty Papers Papers fromfrom 1717--200 g/m200 g/m22
uu CompleteComplete ProductProduct Range Range for the variousfor the various Market Market SectorsSectors
uu International International sales company sales company and Agency and Agency networknetwork
• How do we begin to differentiate “commodity” from “speciality” ?
– Production Capacity
– Added value
– Added technical properties
– Tailor made papers
– End user understanding
Market Requirements of MetallizedPapers
RAW MATERIALSAluminiumPapersLacquers
Commercial Metallizing
PackagingSecurityGiftwrapTobaccoLabel
Barrier Properties Image
Packaging Marketing
Functionality ImageValue
Creation Security
Paper Ingredients
Natural FibresFillers
Water
Additives
A typical Premium Clay Coated Paper for Metallizing ApplicationsCLAY COATING - trimmed for :• Good Lacquering and Metallizing Properties• High Surface Smoothness
(double coating plus calendering)
REVERSE SIDE COATING (optional) - trimmed for :• Optimal Rehumidification• Lay Flat Properties• Specific Smoothness Requirements•Possible Barrier Treatments
BASE PAPER - trimmed for :• High Internal Bond• Lay Flat Properties• Dimensional Stability• Controlled moisture• Low taint and odours• Stiffness•Good die-cutting
Refinements
„One change will always precipate another!“
• Pulp Mix
• Refining
• Additives
• Formation
• Calendering
• Sizing
• Coating
• Lacquering
Paper Making: Fibres' Characteristics
ca. 3,2 mm longca. 0,035 mm wide(pine, spruce)
ca. 1,9 mm longca. 0,022 mm wide(eucalyptus,birch)
Conifers groundwood(fibre bundles)
Pine Spruce
BirchEucalyptus
Long- / short fibre mix
The right choice of fibremix to achieve required product characteristics = determining factor in the art of paper making
Compromise ofStrengthFlexibilityPrintabilityOpacity
Sheet formationLayflatproperties
Cost
Small particles from inorganic substances (chalk or China-clay), which fill areas between fibres.
Fillers
The higher the particle weight, the more filler is washed out during sheet formation. It is therefore difficult to reach a high filler content in the paper.
Fillers do not form any bond with fibres.
Auxiliary Materials and Additives
Paper characteristics can be modified with the addition of chemicals
Important additives
Sizing agents
Wet strength resins
Optical brighteners
uu Scope:– Improve writeability/wetability
– Improve coating bond to surface of base paper through uniform binder absorption into the sheet structure and control of water retention
Ø Surface sizing ð size press
Ø Stock sizing
Sizing of Paper
Water absorption
unsized sized
Wet Strength Resins
• The internal hydrogen bonding of the untreated paper is destroyed after soaking in water. The paper falls apart.
• This can be avoided by adding wet strength resins, thus in wet conditions a certain level of strength can be reached.
• Furthermore, strength and stiffness can be slightly increased.
• The absorption of the paper remains just as it was.
When impregnated with water, hydrogen bonds are dissolved.
By adding wet strength resins, strength in wet conditions can be substantially improved.
Wet Strength Papers
Water content
100% tensile strength
5%
50%
20%
0
without
with wet strength agent
saturated
Assessment of machine direction
MD
MD
CD
MD = Machine Direction
CD = Cross Direction
1st step: Coating
• Pigments (clay, calciumcarbonate, titandioxide)
• Binders (synthetic latex, natural binders like starch)
• Modifiers (improve runnability on coating machine)
• Additives (optical brightener, dye pigments)
What is a Clay Coated Paper?
Top coating Precoating
Reverse side treatment
Base paper
A high-quality kraft paper;mostly douple sided coated,
often (super)calendered
Some coating pigments
ChinaclayChinaclay CCalalcciumiumccarbonatarbonatee
Coatings' Bond Agents
They are responsible for:Picking resistanceAbsorbencyVarnishability
Coating absorptionSealabilityand partly for the paper’s gloss
Bond agents connect the pigment parts with the carrier(base) paper – similar effect to glue.
CC LATEXC STARCHC PVA
Optical Brighteners
Transformation of the invisible UV-light into visible blue-light
• Increase ofbrightness
• Shift from a yellow to a bluish tone
2nd step: Calendering
• Provides coated paper with a high gloss level
• Excellent smoothness
Satinating Calender
GlossmeterGlossmeter
Photo cellPhoto cell
KKüüstersstersrollroll
Steel rollSteel roll
Paper Paper rollroll
Effect finishing on paper properties
LowerHighHighTear strength resistance
LowerHighVery highBulk
LowerHighHighAir permeability
LowerHighHighOpacity
LowerHighVery highStiffness
Very smoothSmoothRoughSmoothness wire side
Very smoothRoughRoughSmoothness felt side
Super
calendered
Machine glazed (1side)
Machine finished
3rd step: Lacquering
• Nitrocellulose, acrylic (some cross linked for beer labels), vinylacetate
• Mostly gravure (reverse gravure)
• Now up to 1200 m/min.
Metallized Labels
Beer labels
• High gloss after metallising
• Alkali resistance
• Ink retention
• Dye cutting properties
• Runnability on beer labelling machines
• Gravure and offset printing
• Layflat properties
• Dimensional stability
Labelcar WS HG, 68 g/mLabelcar WS HG, 68 g/m22
• One side double coated Kraft paper with reverse side treatment
• Wet strength and alkali-resistant
• Excellent properties for metallization
• Excellent surface with high gloss (Gloss Lehmann 75o
WS TAPPI T480 86 %)
• Good results in flexo, rotogravure and offset printing
• Application: High gloss labels for returnable bottles, meeting requirements of the beer industry
Top coat
Pre-coat
Kraft paper
Reverse
Future Trends / Label Papers
• Higher gloss
• Cost reduction
• Combi papers (offset, gravure, bottle neck labelling)
• Better layflat properties and dimensional stability
• Rougher rear side
• Higher ink retention (vision of twice useable labels - recycling)
• Higher speed on bottling machines (40`000 to 60`000 bottles per hour, new 70`000 per hour)
• Special labels (grease proofed papers)
• Special Finishes
Challenges for metallised labels
• Metalure inks !!!
• White labels
• Self adhesive labels (might also be metallised)
• Film labels, direct printing on bottles
Chances for metallised labels
• Achieving a higher difference in gloss level between metallised paper and metalure printed labels!
• Flexibility
Tobacco Products
Inner liner requirements
• High gloss and smoothness
• Low odour and VOC, high purity
• Toxicological properties
• Runnability on cigarette machines
• Runnability on coater and metallizer (low substance)
Innerliner Plus
• One side double coated Kraft paper
• High volume
• Optimal for watery laquers
• No addition of OBA
• Odourless and taint free
• Excellent properties for metallization
• Application. Metallized innerliner for cigarette packs
• Thickness DIN 53105 T1 45 micron Innerliner Plus
• (Innerliner Elite 50 micron)
Top coat
Pre-coat
Kraft paper
Inner liner paper – future trends
• Higher gloss
• Suitable for high-speed cigarette machines
• Lower volatiles
• Increase in water based lacquer systems
• Higher speed on lacquering machines
• Holograms in inner liners
• Security items
• Cost reduction
Challenges for Inner liner
• Metalure inks: but not as serious as on label papers
• Returning to aluminium foils
• New laws that reduce cigarette consumption
Stable requirements expected
Metallized Flexible Packaging
Confectionary
Packaging is changing
Packaging is changing
è
è
è
Giftwrap
Gift wrap / specialities
• High gloss level and high smoothness
• Good mechanical properties
• Properties according to requirements (grease proofed papers)
• High Strength and Bulk
Risks:
• Fashion tendencies
Gift wrap: future trends
• Lower costs
• Higher gloss level and smoothness
• Lower substances with same mechanical strengths
Key Trends
u Consolidation
uLabel Printers
uFlexible Packaging converters
uLaminating
uPressure Sensitive
uTobacco Companies
uFood Producers
Tobacco
Austria Tabac
JTI
Gallaher
Bulgartabac
Tabacalera
BAT
ETI
AltadisReemtsma
Imperial
Philip MorrisSeita Tekel
Tobacco
Austria Tabac
JTI
Gallaher
Bulgartabac
Tabacalera
BAT
ETI
AltadisReemtsma
Imperial
Philip MorrisSeita Tekel
Tobacco
Austria Tabac
JTI
Gallaher
Bulgartabac ??
Tabacalera
BAT
ETI
AltadisReemtsma
Imperial
Philip MorrisSeita Tekel ??
Tobacco
Austria Tabac
JTI
Gallaher /Austria Tabac
Bulgartabac ??
Tabacalera
BAT
ETI
AltadisReemtsma
Imperial /Reemtsma
Philip MorrisSeita Tekel
Flexible Packaging
AMCOR
Sopal
Danisco
Hueck-Folien
PKL
Gascogne
Rexam
Pawag
Tiech
Sopal
Pechiney
Alcan
ConstantiaVAW
Flexible Packaging
Sopal
Danisco
Hueck-Folien
PKL
Gascogne
Rexam
Pawag
Tiech
Sopal
PechineyConstantia
VAW
United Flexible
AMCOR
Alcan / Novelis
How can we develop new trends and applications?u Look at Geographical Regions
Ø Tobacco
Ø EMA / AIMCAL
ØUtilise the new structure to
ØCreate new „joint markets
ØBe creative through „Workshop“
ØAdd Value
Summary
• New challenges in wet strength beer label business
• Rather a stable market in the Cigarette Industry
• Printing / Packing / Conversion speeds
• Changing requirements / trends
• Cost Pressure
The right paper and The right paper and enduseenduse
Metallizing Paper :The Future!
We need to work together to ensure that what is aspeciality material – and make no mistake,
it is a speciality – remains so!
“Use your partners strengths”
Thank You!
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