Old Corrugated Container Research Articles

Circular action treatment (CAT): a new strategy for mechanical treatment of old corrugated container I – effects of control parameters on paper strength

Abstract Circular action treatment (CAT) was developed for improving the strength of paper made from old corrugated containers (OCCs). The effects of the revolution speed of the circular blade, number of passes, and consistency of the stock were studied for application to paper recycling. The slowness, water retention value (WRV), and strength of the paper increased with increasing revolution speed of the circular blades and the passing time without changing the fiber characteristics (length, width, and kink angle) due to the improvement in flexibility and hydration degree of hornified fibers. However, the effect of CAT declined when the stock was passed more than 20 times. The thickening of the stock up to 25 % consistency enhanced WRV and strength of the resulting paper. Below 20 % consistency, the stock adhered to the wall of the CAT apparatus, whereas at higher consistency, the stock could not be treated effectively due to uneven impact. Consequently, when the OCC stock was thickened to 25 % and allowed to free fall from 20 times at the maximum revolution speed (875 rpm) of the circular blades, the strength of OCC paper could be effectively enhanced by CAT.

TEMPO-Oxidized Waste Cellulose as Reinforcement for Recycled Fiber Networks

Lignocellulosic recyclable packaging material is in high demand, because of the emergence of e-commerce. Old corrugated container (OCC) pulp is the main raw material in China for manufacturing pack...

The influence of consistency and fibre length on the yield stress of OCC pulp fibre suspensions

The effect of fibre length on the yield stress of recycled old corrugated containers (OCC) pulp fibre suspensions was investigated. Two types of OCC pulps were divided into four fractions based on the fibre length with a Bauer-McNett classifier. The yield stress of each fraction was measured using the shear stress ramp method at pulp consistency ranging from 0.5% to 2.5% (w/v). The results showed that both pulp consistency and fibre length had significant effects on the yield stress of OCC pulp suspensions, and the yield stress was greater with increasing fibre length and pulp consistency. Moreover, the effect of consistency in OCC pulp suspension with long fibres on the yield stress was stronger than in the slurry with short fibres.

Isolation of bacteria from old corrugated container slime and characterization of their biofilm-forming properties

With the continuously increasing demand for paper and cardboard products, there is growing concern about the bacteria of the papermaking process. Bacterial growth not only affects normal manufacturing, but it also results in paper products with a total number of bacteria that exceeds the acceptable range, and thus poses a risk to the health of consumers. In this study, 99 pure bacterial strains were isolated from old corrugated containers (OCC) slime. The morphological, physiological, and biochemical properties of the bacterial strains were examined. Furthermore, the isolated strains were tested for their ability to form biofilms. The strains that could form biofilms were identified using 16S rDNA sequencing. The results revealed that some bacteria could form both a biofilm that adhered to the smooth tube wall, as well as abundant flocs at the bottom of the test tube. Conversely, the other bacteria could not form a noticeable biofilm. The bacteria with the most powerful biofilm-forming ability were identified as Proteus penneri, Klebsiella variicola, Klebsiella sp., and Proteus mirabilis.

Corrugating Medium Made from Solid Waste of Bamboo Paper Sludge

Corrugating medium was made from the solid waste of bamboo paper sludge and old corrugated container (OCC) pulp. The medium also incorporated additions of anion polyacrylamide as a retention agent and cationic starch as a strengthening agent. The estimated molecular mass of anion polyacrylamide, the addition level of anionic polyacrylamide, and the addition level of cationic starch were optimally designed using single-factor analysis. On this premise, the optimum addition level of the solid waste of bamboo paper sludge was found. The best process conditions for the corrugating medium included a base weight of 120 g/m-2, 10 wt.% bamboo paper sludge solid waste, 0.3 wt.% APAM (Estimated molecular mass of 600 × 104 Daltons), and 1.5 wt.% cationic starch. The apparent density, breaking length, and ring crush index were 0.53 g/cm-3, 2.51 km, and 7.48 N/mg-1, respectively, under the best process conditions. This finding could help satisfy the demand for materials used for making the corrugating medium and could support the full utilization of the solid waste of bamboo paper sludge to achieve higher value.

Effect of surface treatment with biodegradable materials on properties of linerboard made from old corrugated containers (OCC)

Linerboard produced from old corrugated containers (OCC) shows lower strength properties in comparison with linerboard produced from virgin fibers. This study determined the influence of surface treatment with polyvinyl alcohol (PVOH), ethylene vinyl alcohol (EVOH) (as synthesized biodegradable polymers), chitosan, and anionic starch (as biobased and biodegradable polymers) on properties of sheets produced from OCC. The polymers were applied from aqueous biodegradable dispersion, by using a laboratory-scale coater. This research investigated the burst index, tensile index, stiffness, water resistance, air resistance, and water absorption. The results showed that paper surfaces treated with water-soluble polymers increased the mechanical properties. In addition, PVOH increased the burst index value 136% and EVOH increased the tensile index, tear index, and stiffness values by 84.3%, 108.6%, and 22.43%, respectively. The anionic starch increased air resistance to 34.7% and chitosan decreased water absorption to 12.3%.

Fractional pulping of packaging board in high consistency drum pulping

A wide variety of packaging materials with different wetting rates and wet strength properties are used in old corrugated container (OCC) processing. The disintegration rates of the different grades also vary and enable the use of the fractional pulping concept where easily disintegrated material is removed at the early stages. In the present study, fractional drum pulping was studied by pulping (Pilot drum pulping) and fractionating (Tampella oscillating screen) a mixture of strong-grade kraftliner and weak-grade fluting at high consistency to determine if energy consumption could be reduced. The results showed that a 25% energy saving could be realized through fractional pulping and an even higher potential might be possible if pulping conditions are optimized. Average fiber length, fines content, and ash content in the separated fractions were analyzed. The separated short fiber fractions and long fiber fractions could be individually processed, thus decreasing the volumes in the unit processes on the OCC line.

Passivation of pressure sensitive adhesive stickies by addition of acrylic fibers to OCC pulp before papermaking

This study investigated the addition of acrylic fiber to old corrugated container (OCC) pulp as a possible means of overcoming adverse effects of water-based pressure sensitive adhesives during manufacture of paper or paperboard. Such adhesives can constitute a main source of stickies, which hurt the efficiency of the papermaking process and make tacky spots in the product. The highest amount of acrylic fiber added to recycled pulps generally resulted in a 77% reduction in accepted pulp microstickies. The addition of acrylic fibers also increased pulp freeness, tear index, burst strength, and breaking length, though there was a reduction in screen yield. Hence, in addition to controlling the adverse effects of stickies, the addition of acrylic fibers resulted in the improvement of the mechanical properties of paper compared with a control sample.

The Effect of External and Internal Application of Organosilicon Compounds on the Hydrophobicity of Recycled OCC Paper

There are various applications of organosilicon compounds in papermaking. Additionally, organosilicons have been applied to improve the water resistance of some lignocellulosic materials. The performance, however, of such compounds for the hydrophobation of paperboard is unclear. In this study, an organosilicon solution was internally and externally applied to old corrugated container (OCC) paperboard at ambient temperature. Examination of the infrared spectra of treated paperboard confirmed the presence of CH2 groups and hydrophobic organic chains of organosilicon in the treated paperboard. Both internal and external treatment of the paperboard helped its resistance to water, though external treatment was more successful in the late reduction of the contact angle of water droplets and also in reducing water uptake.

Chitosan-Based Reagents Endow Recycled Paper Fibers with Remarkable Physical and Antimicrobial Properties

The aim of the current work was to develop and study a paper additive system that endows recycled paper fibers with strong mechanical and antimicrobial properties. Five different types of modifying agents including succinic acid, carboxymethyladipic acid, butanetetracarboxylic acid, ethylenediaminetetraacetic acid, and diethylenetriaminepentaacetic acid (DTPA) were reacted with soy flour. Approximately 2% modified soy flour additive by mass relative to a old corrugated container (OCC) pulp slurry was mixed before generating a two-dimensional hand sheet for physical testing. DTPA-modified soy-flour-treated OCC pulp displayed better tensile relative to the results from the use of other modifying agents. Soy flour was treated with different DTPA concentrations, times, temperatures, and pH values to determine the optimal modification reaction conditions. Afterward, the DTPA–soy flour was complexed with chitosan to decrease the biodecomposition of soy protein, improve its incorporation into an OCC matrix, and ...

Effects of Montmorillonite Clay on Mechanical and Morphological Properties of Papers Made with Cationic Starch and Neutral Sulfite Semichemical or Old Corrugated Container Pulps

The impact of montmorillonite (nanoclay) addition on the mechanical and morphological properties of paper made from neutral sulfite semichemical (NSSC) and old corrugated container (OCC) pulps was evaluated in systems utilizing cationic starch for dry-strength. The nanoclay amount was considered at five levels, and cationic starch was applied at a 1% level. In OCC pulp, by increasing the nanoclay up to 4%, the tensile index and corrugating medium test (CMT) were increased; however, there was a decrease when the nanoclay was increased to 8%. By increasing the nanoclay to 2%, the tear and burst indexes and ring crush test (RCT) increased, but there was a reduction when the nanoclay was increased to 8%. Average air resistance tended to increase as the nanoclay was increased to 8%. In the case of NSSC pulp, by increasing the nanoclay amount from 0 to 8%, the average tensile, tear, and burst indexes decreased, while the air resistance increased. The CMT amount increased with increasing nanoclay content to 2%, but a reduction was seen for other levels. The RCT exhibited an increase with increasing nanoclay up to 4%, after which it decreased. Results suggest that the proportion of nanoclay added with cationic starch needs to be optimized, depending on furnish conditions.

Energy Savings and Strength Improvement of Old Corrugated Container by Application of Wood Flour and Starch

ABSTRACT The increase of wet web solid content after wet press and dry compressive strength were observed in lab study by judicious application of wood flour and starch for the old cor-rugated container (OCC). Pearl starch was better than cationic starch in strength devel-opment, but cationic starch was better for drainage. Application of vacuum on the mixed solution of wood flour and starch helped strength development further without loss of other properties. The effect of wood flour addition on wet web solid content improved as the wet pressing pressure increased. The use of wood flour and starch mixture improved wet web solid contents further.Keywords: OCC, wood flour, starch, wet pressing, compressive strength • 충남대학교 농업생명과학대학 환경소재공학과(Dept. of Biobased Materials, College of Agriculture and Life Science, Chungnam Natl. Univ. Daejeon 34134, Republic of Korea) † 교신저자(Corresponding Author): E-mail: ybseo@cnu.ac.kr http://dx.doi.org/10.7584/ktappi.2016.48.2.099Journal of Korea TAPPIVol. 48. No. 2, 2016, 99-105pISSN (Print): 0253-3200Printed in Korea

RECYCLING NEWS

With its infamous bureaucracy, legions of news organizations, and the prominence of the federal government, Washington, D.C., and its environs generate literally tons of paper every day. Paper represents almost 40% of the waste stream, according to the US EPA. The agency`s figures show that more than 80 million tpy of paper are generated, and with such a significant portion of this waste capable of being recycled, it is essential that the nation`s capital have enough paper recycling facilities. Capital Fiber (Springfield, VA.), a large-scale intermediate paper processing facility, is an example of one such facility. Its primary material is old newspapers (ONP), and its operations consist of receiving, sorting, and consolidating waste paper for baling and resale. The company is a joint venture between daily newspaper giant the Washington Post (Washington, D.C.), which owns 80%, and the Canusa Corp. (Baltimore), a waste paper brokerage firm, which owns the other 20% of Capitol Fiber. Capital Fiber`s Springfield facility handles nine grades of paper, including pre-consumer and post-consumer ONP, blank news (newspaper trimmings that have not been printed on), old corrugated containers (OCC), sorted white ledger and sorted office waste, and various wrappers, supermixes, and other mixed grades. Within each ofmore » these categories are various sub-grades of paper, and the facility also takes old telephone books, computer paper, and flyleaf, the extra tim cut from periodicals. But, not surprisingly, the predominant material is ONP.« less

Press wetting as an enhanced wetting method for baled OCC material

A procedure to mechanically force water into the bale structures of old corrugated container (OCC) material was studied and evaluated in low-consistency pulping studies. Two mechanical methods were used in the study: (1) roll pressing of sheets and (2) press wetting of bales. Mechanical pressing was first used in simple roll tests to evaluate nip pressure as an enhanced effect on wetting. Repeated press wetting treatments were found to increase water penetration into the sheets and appeared to lower wet strengths. A simple laboratory-scale bale pressing device was constructed and the effect of different parameters in wetting method was studied. We found that when a bale was pressed under water, multiple pressings were needed to get efficient press wetting. Increased temperature was found to increase water penetration inside the porous structure of linerboard. We also discovered that there must be a delay between relaxation and pressing to allow water to travel within a board and to wet all surfaces. The wetting procedure also evaluated the weight of water inside the bale. Results showed that the amount of water could be used as an indicator of the pulping kinetics and energy consumption needed to disintegrate OCC. The enhanced method (i.e., hydraulic pressing) could provide efficient wetting on an industrial scale. With this method, a 30% savings in the energy consumption required in pulping unit operation is possible.

Rice Husk and Old Corrugated Container Cement Boards: Performance of Nano-SiO2 on Strength and Dimensional Stability

In this study the effect of nano sized silica particles (nano-SiO2) on the physical and mechanical properties of rice husk and Old Corrugated Container (OCC)-cement boards was investigated. Modulus Of Rupture (MOR), Modulus Of Elasticity (MOE), Internal Bonding Strength (IB), density, water absorption and thickness swelling after 24 hours immersion in water and hardness were measured. Results showed that rice husk-cement boards with 2% nano-SiO2 demonstrated the best physical and mechanical properties. It is related to better distribution and compaction of particles during compression without particles agglomerating. A higher property of 2%-nano-SiO2 content rice-husk-cement boards was confirmed by their higher hydration temperature. Addition of 3% nano-SiO2 to the mixture reduced the density because of both the substitution of denser cement particles by lighter nano-SiO2 particles and air-entrapment in the boards. Furthermore, Scanning Electron Microscopy (SEM) analyses showed that the optimum amount of nano-SiO2 (2%) can fill micro pores and make a uniform structure with a rough surface which improves properties of composite boards.

Properties of Bleached Pulps from Low and High Kappa Number Old Corrugated Containers (OCC)

Department of Fibrous Raw Materials and Pulps Technology Institute of Papermaking and Printing, Lodz University of Technology, ul. Wolczanska 223, 90-924, Łodź, Poland, Contact: www.pulppaper.eu Abstract The strength, structural, optical and water absorption properties of bleached pulps from unprinted, low and high kappa number old corrugated containers (OCC) were determined. The results were compared with the properties of bleached birch pulp and pine pulp. It was found that old corrugated containers pulps show higher Shopper-Riegler freeness, distinctly lower tensile strength, and lower maximum short-span compressive strength (SCT) than birch and pine pulps. However, they also show quite good tear resistance, optical properties, bulk and water absorption. In order to explain the differences in the properties of bleached OCC pulps and birch and pine pulps, they were evaluated using image analysis. This study showed that OCC pulps contain both long softwood and short hardwood fibres, with a predominance of the former. An analysis of the lower tensile strength of OCC pulps was also made. It was established that it is mainly caused by the lower degree of polymerisation (DP) of cellulose and the higher degree of damage of OCC fibres.

The interaction of delignification and fiber characteristics on the mechanical properties of old corrugated container fiber/polypropylene composite

AbstractThe effect of fiber characteristics from old corrugated container (OCC) paper on the strength properties of OCC/polypropylene composites was evaluated. Fibers with different contents of lignin (2.8%, 3.8%, 5.3%, and 7%) were produced using soda pulping. Wettability, tear, and tensile strength of the fibers were measured as the indication factors to assess the strength of reinforcing component in the composites. The weight portions of the OCC fibers, polypropylene, and maleic anhydride-grafted polypropylene (MAPP) were selected at 20%, 77%, and 3% of the total weight of the composite, respectively. The composite compounds were formed using a counter-rotating twin screw extruder, and the specimens were made in an injection molding machine. The interaction of fiber characteristics and fiber lignin content on the mechanical properties of composite was investigated. The results revealed that with lower fiber lignin content, both flexural and tensile properties were increased. Consequently, by forming better fiber dispersion and by reducing stress regions in the composite, impact strength was also improved. Lower lignin content resulted in better mechanical properties than fiber characteristics.

Extraction of cellulose nano-crystals from old corrugated container fiber using phosphoric acid and enzymatic hydrolysis followed by sonication

Due to its amazing physicochemical properties and high environmental compatibility, cellulose nano-crystals (CNC) hold great promise for serving as a strategic platform for sustainable development. Now, there has been growing interest in the development of processes using waste or residual biomass as CNC source for addressing economic and environmental concerns. In the present work, a combined process involving phosphoric acid hydrolysis, enzymatic hydrolysis and sonication was proposed aiming to efficiently exact CNC from low-cost old corrugated container (OCC) pulp fiber. The effect of enzymatic hydrolysis on the yield and microstructure of resulting CNC was highlighted. Results showed that the enzymatic hydrolysis was effective in enhancing CNC yield after phosphoric acid hydrolysis. CNC was obtained with a yield of 23.98wt% via the combined process with phosphoric acid concentration of 60wt%, cellulase dosage of 2mL (84 EGU) per 2g fiber and sonication intensity of 200W. Moreover, the presence of enzymatic hydrolysis imparted the obtained CNC with improved dispersion, increased crystallinity and thermal stability.

Utilization of Wood Flour for Drying Energy Saving of Old Corrugated Container

The increase of wet web solid content in wet pressing will save drying energy greatly. We applied wood flours as spacers to increase the old corrugated container (OCC) solid contents in wet pressing. The mixed furnish of OCC and wood flours of 3-5% (wt/wt) increased bulk and drainage rate, and by increasing wet pressing pressure, its solid content started to be higher than 100% OCC furnish at more than 50% solid content level. Addition of cationic starch and drainage aid to the mixed furnish increased solid content further up to around 2%. Cationic starch addition compensated or exceeded the loss of tensile and compressive strength caused by the addition of wood flour, but drainage aid did not. Cationic starch also improved the stretch of the OCC, which could mitigate cracking at folding in boxboard.

A preliminary assay of the potential of soy protein isolate and its hydrolysates to provide interfiber bonding enhancements in lignocellulosic furnishes

Soy protein isolate (SPI) was extracted from soy flour and hydrolyzed with hydrochloric acid, sodium hydroxide, and enzyme, separately, to provide a series of hydrolysates. The SPI and its hydrolysis products were later cross-linked with ethylendiaminetetraacetic acid (EDTA) in the presence of sodium hypophosphite (SPH) after which they were complexed to chitosan as part of an on-going general chemical strategy in our laboratories to improve their incorporation into old corrugated container (OCC) matrix and thus increase inter-fiber bonding. Approximately 2% SPI-EDTA-chitosan and hydrolyzed SPI-EDTA-chitosan additives by mass (OCC-based slurry) were thoroughly mixed before generating a sheet for physical testing. The tensile and burst indices of the SPI-EDTA-chitosan additive-treated OCC pulp sheet increased 46.3% and 61.85%, respectively, while the inter fiber bonding of SPI-EDTA-chitosan additive-treated OCC pulp sheet increased 74.86% compared to the control, albeit having a decreased tear strength and roughness, with significantly increased gloss. The additive-treated pulp sheet was characterized by thermogravimetric analysis (TGA), dynamic mechanical analysis (DMA), and ATR to provide evidence for product synthesis.