These days, cooperation between entities is often worldwide and the technologies that result know no boundaries
July 2008
By Shelley Strickland, freelance writer
Today’s business is more global than ever. Issues in the paper industry are becoming problems for paper producers on a worldwide basis. That’s why solutions to such problems must fit not only one region of the world, but also translate from country to country.
Companies such as the The Dow Chemical Company are working to develop solutions for customers that make sense on a global level. Dow frequently cooperates with leading external research institutes to generate a fundamental understanding of important technical problems and then uses this understanding to develop breakthrough solutions for the paper and coating industry that can be used anywhere in the world.
Eliminating Fold Cracking
For example, the company recently joined forces with Abo Akademi University in Finland to address the need for fold crack resistance in the manufacture of coated paper-based products such as magazines, books and cartons, where folding operations are required. Representing nearly 40% of quality complaints from web-offset printers, “fold cracking” is one of the most frequent problems and is both an aesthetic and functional issue.
The Dow Emulsion Polymers team led by Dr. Pekka Salminen, Global Application Technology Leader, in cooperation with research experts at the university conducted a two-part study on optimizing the balance of stiffness and fold cracking for coated paper. For Dow, this research enables the company to respond to an important customer concern. For the university, the study provides insight on how a practical problem is linked to a solids mechanics issue that has scientific value in general.
“Having a long-term, strategic cooperation between our laboratory and Dow makes it possible to start smaller and larger projects fairly quickly,” says Dr. Martti Toivakka, with the Center for Functional Materials Laboratory of Paper Coating and Converting at Abo Akademi University. “We understand each party’s needs and motivations, and Dow knows our strengths in research.”
In this study, the triple coating simulations showed that a thin, stiff bottom layer can be allowed to crack with a thick, middle layer acting as a buffer absorbing the crack. This enables the use of a relatively stiff binder in the outer layer that contributes to the stiffness. The combination of layers allows one to achieve a higher level of stiffness than any of the double layer coating combinations while retaining good fold crack resistance. Ultimately, these studies proved to be a “triple threat” to fold cracking and a positive development for Dow customers.
“Working with external research groups like Abo Akademi allows for an amazing partnership and opportunity to continually provide our customers with the best products possible,” says Salminen. “As a leader in science and technology, Dow is always focused on developing innovative and cutting-edge solutions to improve the processes and products that concern the paper industry today and into the future.”
The results of the fold crack study were first presented September 2007 at the PTS Coating Conference in Germany, and the proof of the global importance of the fold crack topic was revealed at the PaperCon 2008 conference in Dallas, TX. Dow’s presentation on this fold crack study took home the TAPPI best paper award.
“This was an excellent piece of scientific and technical research that helped explain and offer practical guidance to the industry on how to resolve the issue of fold cracking,” says Dow Global Tech-nical Leader Rainer Knappich. “It’s a great example of how science and technology can create a real dollar value for the paper industry.”
A World Without Borders
To further focus on developing innovative solutions to global challenges for paper producers, Dow will soon open its new Center of Excellence for Paper and Board Coating located in Samstagern, Switzerland. The center will allow for increased capabilities to meet growing customer needs and will be available to support Dow’s customers worldwide. It features pilot coating equipment for coating operations, and includes facilities to develop and test coating components, coating formulations and machine running conditions. Customers around the world can conduct real-life production simulations without interrupting commercial production times.
“Paper producers can use these trials either to improve cost and performance of existing products or to develop new paper grades,” says Christian Page, Dow global paper and board director. “Both are critical for our customers to stay competitive in their markets around the world.”
The result of such trials is the development of solutions and new technologies that can be applied to the paper industry on a global basis or from one country to another. For example, Dow may develop products for use in Europe and later introduce them to the North American market or vice versa. Based on Dow’s global polymer and application development efforts, the company introduced several latex technologies at PaperCon 08. All designed to deliver superior strength, gloss and overall performance, these technologies include: MaxForte, ProForte, ProStar, RotoPrint, MaxFoS.
By thinking globally, Dow and its customers are able to produce paper products that respond to industry demands and result in a better product – no matter where you are in the world.
Shelley Strickland is a freelance writer who frequently covers chemical-based technologies. She is based in LaGrange, GA.
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