Alkyl ketene dimer (AKD) and rosin sizing are used in papermaking to decrease paper’s tendency to absorb liquid water. Earlier information regarding the effects of internal sizing on paper dry strength is not consistent. In the present laboratory study, AKD sizing of handsheets made from Nordic bleached softwood pulp (NBSK), and rosin sizing of handsheets made from Nordic hardwood chemi-thermomechanical pulp (CTMP) were done via an internal sizing method, and by immersing handsheets in aqueous sizing agent dispersion. In the study, AKD sizing had no significant effect on the dry strength of NBSK handsheets. The result corresponds to practical experiences of papermakers. However, both AKD sizing methods resulted in a substantial and long-lasting increase of handsheet wet-strength. Unlike internal AKD sizing of NBSK handsheets, rosin internal sizing of CTMP handsheets resulted in decreased handsheet dry strength. The decrease indicates that, under the conditions present during the experiment, rosin sizing agents interfered with interfiber hydrogen bonding of CTMP fibers. Given that, in practice, no such undesired effects have been commonly linked to rosin sizing, the observed effect may be specific to sheet-making conditions. However, the effect of rosin sizing on strength properties and their variation cannot be ruled out completely.

Polyamide-epichlorohydrin (PAE) is used in papermaking to increase the paper’s wet strength. High levels of PAE can make repulping of paper more difficult. PAE deposits can also impair paper machine performance by plugging the paper machine felts. The results of a preceding study indicated that the wet strength of paper containing a moderate amount of PAE (added amount 0.3 wt%) can be increased by utilizing internal alkylketene dimer (AKD) sizing. In the present study, the effects of an added amount of PAE and AKD on the wet strength of handsheets made from Nordic bleached softwood pulp (NBSK) were examined. The wet strength was measured after soaking the sheets in ion-exchanged water for up to 1 month. The improving effect of AKD sizing on the wet strength was long-lasting and it was apparent especially with a low and moderate added amount of PAE (0.15 and 0.45 wt%) resulting in higher wet strength than the highest added amount of PAE (1.35 wt%) alone. No clear sign of worsened repulpability was observed at low to moderate treatment levels. The results suggest that use of small or moderate amounts of PAE with AKD can be a viable option for paper mills facing problems related to the high usage of PAE.

No abstract

This paper summarizes recent developments in foam forming that were mainly carried out in pilot scale. In addition to improving the efficiency of existing processes and allowing better uniformity in material, a wide variety of raw materials can be utilized in foam forming. The focus of this paper is thin webs—papers, boards and foam-laid nonwovens, along with the pilot scale results obtained at VTT in Finland. For paper and board grades, the most direct advantage of foam forming is the potential to produce very uniform webs from longer and coarser fibers and obtain material savings through that. Another main point is increased solids content after a wet press, which may lead to significant energy savings in thermal drying. Finally, the potential to introduce “difficult” raw materials like long synthetic or manmade fibers into a papermaking process enables the manufacturing of novel products in an existing production line. This paper also briefly discusses other interesting foam-based applications, including insulation and absorbing materials, foam-laid nonwovens, and materials for replacing plastics.

In addition to carding and airlaid processes, nonwovens are produced from staple fibers by a wet-laid process. A drawback of this process is the necessity to use very dilute fiber suspensions to avoid fiber entanglement and consequent poor fiber web uniformity. As a result, flow volumes are very high and process speeds are rather low compared to water forming used in the paper and board industry. A promising option for making nonwovens is foam laying. The bubbles in foam keep the fibers apart until the foam is removed, and much higher fiber weight consistencies can be used compared to traditional wet laying. A key challenge in foam forming of nonwovens is to obtain uniform dispersion of the fibers in the foam. In this work, we studied this with 24-mm staple fibers, and analyzed the homogeneity of the obtained foams by making fibrous sheets from them in a laboratory sheet mold. We found that dispersion was highly dependent on the mixing conditions, such as mixing time, foam air content, and fiber weight consistency. Remarkably, excellent fiber disintegration and uniform sheets were obtained without mechanical pre-treatment of staple fibers, with fiber consistencies as high as 0.3%. By comparison, conventional wet-laid processes typically operate with fiber consistencies lower than 0.05%. Thus, at an industrial scale, foam forming promises production of uniform webs from stable fibers with clearly lower water volumes and possibly also higher machine speeds compared to conventional wet-laid forming.