Paper MiddlEast n°18 13 by ENP Publishing

magazine

Edito

PAPER MIDDLEAST pulp, paper, tissue

The Magazine dedicated to the Pulp, Paper and Tissue Industry in the Middle East

The future starts today

N°18 - Winter 2012

Head Ofﬁce / Publisher ENP SA info@groupenp.com 36, rue Stanislas Julien - 45000 Orléans France Tél. +33 238 42 29 00 Publisher STÉPHANE RICHARD stephane.richard@groupenp.com Correspondants Lebanon RIMA DIB rima.dib@groupenp.com Egypt YASSER ZAKARIA sales@yzgroup.org Syria AHMED AL SLEEBA ahmed.sleeba@groupenp.com Jordan RAMI HOURANI rami.hourani@groupenp.com Advertising Middle East rima.dib@groupenp.com Tel: +961 32 24 953 International Advertising STÉPHANE RICHARD stephane.richard@groupenp.com FRANÇOIS HÉNIN francois.henin@groupenp.com Tel: +33 238 42 29 00 Fax: +33 238 42 29 10 Graphic Designers ELHAM EL MASRY GHALI SIMON & PARTNERS

he years go by, but things seem to remain unchanged. The past 12 months should have seen the global economy restructured, according to the new political deal that was expected in many parts of the world. The truth is that national initiatives are not sufficient to reform the global interconnected system we live in. And the lack of visibility and confidence in the future, still affect the prospects of a rapid recovery in the western countries. When it comes to the Middle East region, the situation is quite mixed. In 2012, some countries will have performed much better than others, with an annual growth ranging from 1.2% to 5.3%, oil exporters having been favored. The projections for 2013 show more concentrated figures going from 3.1% to 3.6%. The countries in transition after the “Arab spring” are still facing economic and political strains. They are struggling to find a way to stabilization and prosperity. While the hectic situation in Syria affects its neighboring nations. However, the growing demand for products of a higher quality, in conjunction with the need for an improved productivity, lead to some investment projects in the paper, board and tissue industry. In a region where overcoming adversity has become part of the culture, this is a sign that, whatever the turmoil, political leaders appear to have little impact on the real economy. This entrepreneurship spirit is a key factor for keeping afloat in a challenging and turbulent environment. Let’s all build our future every day. Happy New Year!

Subscription MATHILDE SEVESTRE mathilde.sevestre@groupenp.com Diffusion : 3.000 ex. Algeria, Bahrain, Egypt, Iran, Irak, Jordan, Kuwait, Lebanon, Morocco, Oman, Qatar, Saudi Arabia, Syria, Tunisia, United Arab Emirates, Yemen www.groupenp.com Ofﬁcial Media Partner

2012

S. Richard stephane.richard@groupenp.com papermiddleast 3

Advertisers Index Algas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31, 44 APA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58, 67 BTG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15, 53 Fibretec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4, 40

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IPT Istanbul 2013 . . . . . . . . . . . . . . . . . . . . . . . . 25 Roquette . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-35 Tissue World Barcelona 2013 . . . . . . . . . . . . . . . . 2

Contents

Paper Middleast 18 Winter 2012

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5L^Z 6

Metso to supply board machine rebuild for Obeikan Paper Industries in Saudi Arabia

PMT Italia to Rebuild PM 1 for United Paper Industries in Kuwait

Breakthrough: Metso Pulp Analyzer helps papermakers predict paper properties

Sipat started up PM2 in Meknes, Morocco, after a major rebuilding

MeadWestvaco Completes Acquisition of Ruby Macons

Technology 16

Food packaging 20

Yasser Zakaria Group awarded global quality awards by international panel

PSPJVUL *VH[PUNZ 6Ä&#x192;LY 5L^ 6WWVY[\UP: ties for Food Contact Paper Performance

Events 24

Paper Arabia 2012 concludes with 90 % bookings for next edition

The three day exhibition had witnessed an unexpected success that had surpassed all expectations

Bellmer Paper Days

Tissue World 2013 in Barcelona

Award 10

Cutting through the foam, with minimum chemical cost

Interview 12

Misr Edfu Deep rooted history... Unique present

papermiddleast 5

News

SAUDI ARABIA

Metso to supply board machine rebuild for Obeikan Paper Industries in Saudi Arabia Metso will rebuild the PM 1 cartonboard machine at the Riyadh mill of Obeikan Paper Industries in Saudi Arabia. The rebuilt production line will be fully operational in the middle of 2013. The value of the order will not be disclosed. The main target of the rebuild is to improve end product quality, increase capacity and reduce production costs. “This investment is aligned with Obeikan strategy to keep the mill up-to-date in technology in order to keep feet within the competitive environment of paper industries,” says Mohammed Al-Mowkley, General Manager of Obeikan Paper Industries. The coater and air system rebuild order is included in Metso’s Pulp, Paper and Power third quarter 2012 orders received and the press section rebuild order is included in the second quarter 2012 orders received.

KUWAIT

PMT Italia to Rebuild PM 1 for United Paper Industries in Kuwait United Paper Industries Co. has selected PMT Italia as the supplier of a major rebuild of their PM1, located in Shuaiba Industrial Area, Kuwait. The 2.6 meter-wide machine produces sack kraft as well as ﬂuting and test liner and uses locally sourced OCC (Old Corrugated Containers) as its primary raw material.

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According to PMT, the rebuild is expected to improve the paper machine’s production capacity and enhance paper strength properties. Start up is planned for the fourth quarter of 2013, PMT said.

WORLD

Breakthrough: Metso Pulp Analyzer helps papermakers predict paper properties The new Metso Pulp Analyzer (Metso MAP) features the first on-line measurement of microscale details of fiber properties. It provides pulp and papermakers a tool that helps to predict how fiber properties will affect final sheet strength properties. The new analyzer also enables precise furnish preparation and low consistency refining management resulting in better sheet runnability, higher machine efficiency and lower furnish costs. Metso introduces the next generation’s pulp analyzer (Metso MAP) that features a new high definition fiber imaging module. This module represents the first on-line measurement of micro-scale details of fiber properties, including fibrillation, vessel segments, flocs and other particles. The fibrillation measurement, combined with other fiber properties measured by the analyzer, can be processed in a modeling tool that helps to predict how fiber properties will affect final sheet strength properties. This next generation’s analyzer provides online measurement of fiber dimensions including kink, curl, size distribution and fractionation. The Metso MAP has established an excellent reputation for measurement accuracy and reliability in the pulp and paper industry. Several advantages for pulp and paper makers The new product is intended for managing fiber properties in papermaking furnish preparation as well as in mechanical, recycled fiber and

News

kraft pulp mills. To provide the highest measurement application flexibility, the analyzer samples from up to 20 process fiber streams. This new analyzer also utilizes brand new manual sampling stations that can be located throughout the plant. To date, the product has been installed in paper, tissue and board mills. With a freeness measurement module included in the same platform, the Metso MAP provides pulp and papermakers with a quickly updated and complete fiber and furnish measurement solution. More precise furnish preparation and low consistency refining management provides better sheet runnability, higher machine efficiency and lower furnish costs. Pulp mill operations will benefit from minimum shives in mechanical and chemical pulps, and reduced fiber quality variability. In addition to providing operators with an unprecedented window into pulp quality, these measurements are an integral part of pulping and refining controls.

in over 50 countries deliver sustainability and profitability to customers worldwide. Expect results. The Automation segment’s process automation and flow control solutions meet the growing needs of Metso’s customer industries to improve production process efficiency as raw materials and energy sources become scarcer and their costs increase. Our global network of service experts delivers business solutions to our customers that improve their productivity, lower risks and optimize costs. www.metso.com, www.twitter.com/ metsoautomation.

MOROCCO

Sipat started up PM2 in Meknes, Morocco, after a major rebuilding

Flexible and modular design The Metso MAP builds upon a flexible and modular design. Already installed analyzers can be upgraded easily with the new high definition fiber analysis module. This underlines the original analyzer design philosophy which allows for upgrading the platform as new technology becomes available without making the original investment obsolete. The useful lifecycle of the product is thereby extended. To ensure maximum uptime and process measurement performance, the Metso MAP analyzer has been designed with remote access and service support in mind. From anywhere in the world a Metso expert can access an analyzer - with permission and through a secure access port - and work out a solution to technical and process applications very quickly. Metso is a global supplier of technology and services to customers in the process industries, including mining, construction, pulp and paper, power, and oil and gas. Our 30,000 professionals based

The Moroccan tissue producer Sipat has successfully started up PM2 machine in Meknes after a major rebuild. The Italian company Toscotec has been the supplier of the rebuilding of the existing PM2 in crescent former. The dry end of the same PM2 was rebuilt in 2009 by Toscotec too. The Sipat TM 2 started up smoothly according to the time schedule and produced a good-quality saleable product from the very beginning. Sipat S.A. - Societé Industrielle Des Papiers Tissues, established in 1978, is owned by the El papermiddleast 7

News

Kendouci family. With a production capacity of 16.000 tpy, the company can satisfy the request of the Moroccan market, capable of absorbing 70% of SIPAT’s capacity, and exports the rest to other African markets. The production range includes mainly facial tissue, toilet rolls, napkins, and kitchen towels. Toscotec’s delivery included a major rebuild of the original Toschi sloped wire forming section, which has been replaced by a MODULO Plus type crescent former with TT HEADBOX SL-T, a modernization of the existing approach system and of the felt run as well as YD doctoring system. Furthermore electriﬁcation and a new machine control system completed the package. The project was handled on a turnkey basis, including dismantling of the existing equipment, installation of the new machinery, start-up assistance and training services. The new machine parts have been designed for an operative speed up to 1300 mpm with a reel width of 2750 mm. The purpose of the PM2 rebuilding was to meet the regional growing market demand in terms of products quality and production capacity with an increased output, as well as to reduce energy consumption. The fast delivery and installation timing combined with very good performances of the machine few days after the start up underline once more Toscotec leadership not only in providing capital projects to the tissue industry with innovative energy-savings concept, but also in managing complex and integrated rebuilds with fast pay-back time for the ﬁnal customers.

INDIA

MeadWestvaco Completes Acquisition of Ruby Macons MeadWestvaco Corporation said that it has completed the purchase of Ruby Macons 8 papermiddleast

Limited. The India-based producer of highquality corrugated packaging materials becomes a central component of MWV’s packaging platform in India and a key element of the company’s plans to grow in emerging markets. The transaction was completed on Nov. 30, 2012 and financial results for Ruby Macons will now be reported as part of MWV’s Industrial Packaging segment. Ruby Macons is the market leader in corrugated packaging materials in India. The company currently produces over 150,000 tons of containerboard annually at two mills containing three paper machines in and around the city of Vapi, Gujarat. These assets, as well as a significant expansion project underway, will significantly increase capacity and accelerate MWV’s profitable growth in this fast growing region, MeadWestvaco said. “We are excited to welcome Ruby Macons into the MWV family, marking an important step forward in our long-term commitment to growth in India,” said Peter C. Durette, senior vice president and chief strategy officer for MWV, who oversees the company’s business in India. Under the terms of the deal, all Ruby Macons employees will become MWV India employees and the Ruby Macons management team will remain in place, including Mr. Ashraf Nathani, managing director, Ruby Macons, who becomes vice chairman and president of the business. The acquisition of Ruby Macons expands MWV’s presence in industrial packaging in India, which also includes a converting facility in Pune making rigid, humidityresistant corrugated packaging for fresh fruits and vegetables, consumer goods, household appliances and pharmaceuticals. MWV also delivers innovative packaging solutions for a variety of consumer goods markets in India, including Healthcare, Beauty & Personal Care, Home & Garden, and Beverage. It also markets specialty chemicals for asphalt paving and other specialty chemicals markets.

Award

Yasser Zakaria Group awarded global quality awards by international panel. Yasser Zakaria Group earned the opportunity to be granted one of the highest international awards “IAE International Arch of Europe Award - Gold Category” and “QC100 Total Quality Management Model” awarded by BID Business Initiative Directions for high standard and professionalism demonstrated by prestigious performance in all its commercial business and administrative activities.

asser Zakaria Group is a group of companies offering many services for paper, carton and tissue industry in the Middle East. With “The complete solutions for paper industry” as a slogan, the Group provides complete services for every kind of paper manufacturing, from complete production lines and machines, to equipment, spare parts and consumables required for new or existing mills. Also, the group provides marketing services and consultancy for international exhibitions and conferences, media and magazines, all related to the paper industry. Besides, showing its commitment to the paper industry in the region, the YZ Group founded the “Arab Paper Academy” to provide specialized training programs and courses for those who work, or wish to work, in the paper, carton and tissue plants. A wide range of courses and diplomas are provided along with practical training in cooperation with foreign universities and institutes. Freshly graduated engineers, chemists and 10 papermiddleast

technicians can improve their knowledge and match with the latest technology in order to become a highly qualified professional of the papermaking process, who can run production lines and supervise the production phases. Business Initiative Directions is a leading private organization awarding companies worldwide. They chose Yasser Zakaria Group on the basis of a voting process carried out among all the participating former awardees in a confidential voting process. The final decision to award YZ Group, made by the IAE Selection Committee is based on studying its performance in aspects like Customer Satisfaction, Communication Strategies, Leadership, Planning and Decision-making, Human Resources, Processes and Production, and Financial Outcome. The convention and presentation of the 2012 International Quality Award took place on April 30th in the Hotel InterContinental, in Frankfurt, where the awards and certificates were presented to the awarded companies from over 173 countries. “The awarded companies are symbols of commitment to lea-

dership, technology, and innovation, making them models for others in their sectorsâ&#x20AC;? said Jose E. Prieto, President of B.I.D. Also, QC100 model of Total Quality management was given to the awarded companies in recognition of their achievements in spreading Quality Culture in all its internal and external sectors. BID Business Initiative Directions has main principles of quality managements all over the world, and when these principles are applied by any company, it commits to publicizing this quality culture to all its administrations, and so it becomes a Quality Managements Model.

1. Quality is a consequence of valuing customer satisfaction and obtaining positive business results. 2. Meet the quality levels established in the company in accordance with the QC100 Points of Quality. 3. Encourage participation and teamwork for decision making. 4. Satisfy the needs of our clients and meet their expectations. 5. Provide human resources, both technical and economic, to achieve continuous improvements and respect for the environment 6. Manage human resources in our company to achieve the maximum potential. 7. Make the employees aware of the importance of concentration on the most proďŹ table areas of activity, to achieve the best business results. The achievements of these seven principles by Y Z Group will foster improvements for clients, employees, suppliers, and all of the other persons who make up the company. And so Yasser Zakaria Group deserved to get QC100 Total Quality Management Model.

These principles are:

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Interview

Misr Edfu Deep-rooted history... Shining present From our correspondant in Egypt, Yasser Zakaria

lso known as MEPPCO, Misr Edfu is one of the biggest producers in Egypt, manufacturing pulp, as well as bleached and unbleached writing and printing paper. Since it started in 1963, Misr Edfu production has been on a high standard. It rapidly became one of the major paper suppliers for local companies, serving publishing houses, printers and government agencies, and exporting to Arab and African markets...

worked in the paper industry from the very beginning of his career, gaining a valuable and unmatched experience.

This success partly relies on the motivation of a high-skilled staff, and especially the manager of the mill, Eng. Mohamed Abd Allah, who has

It all started when I decided to become a chemist engineer after joining the faculty of Engineering. After graduation I got my ďŹ rst job at

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Eng. Mohamed Abd Allah accepted to answer the questions of Paper MiddlEast Magazine and deliver his vision to our readers. s &IRST OF ALL CAN YOU TELL US A BIT ABOUT YOURSELF AND YOUR CAREER

Misr Edfu Pulp Mill. This was in 1985. Through all these years I have held many positions while working in this mill, from Junior Engineer, to Production Manager, and to Mill Manager, my current position. s -ISR %DFU #O IS A MAJOR PLAYER OF THE %GYPTIAN PAPER INDUSTRY #AN YOU GIVE US MORE DETAILS ABOUT THE COMPANY S HISTORY AND PRODUCTION The ďŹ rst pulp mill was established in 1963 in Egypt, and in 1986 they made a study which stated that the Egyptian market needed more paper mills, recommending the construction of a new paper mill, next to the existing paper mill belonging to Misr Edful. This new mill was completed in 1997, and started-up with a production of 60,000 tons/year of 50gram paper. Later, in 2007, we made another study which concluded that the main paper producers in Egypt, Rakta Paper Mill, Quena

Paper Mill and Misr Edfu Mill, were producing about 50% of the Egyptian market demand. So, once again, Misr Edfu decided to increase its production capacity by developing and expanding the existing mill. This project came with the creation of a new converting mill. s (OW MUCH DOES THE %GYPTIAN MARKET COUNT FOR -ISR %DFU COMPARED WITH THE EXPORT SALES In 2010 we exported 30,000 tons, which represent 50% of our total production. But in fact, exporting is not a priority for us, as we are more competitive and proďŹ table selling the production with a local price, so Misr Edfu tends to sell the majority of the production on the Egyptian market. s 7HAT KIND OF RAW MATERIALS ARE USED IN -ISR %DFU -ILLS We are mainly using 75 â&#x20AC;&#x201C; 80% baggas and 25% wood pulp. But this year we suffered a lot from the lack of baggas, so we had to increase the wood pulp to 33%. s 7HAT ARE THE FUTURE PLANS OF -ISR %DFU We have led many projects to improve the process of our production lines, all aiming at increasing the production capacity and improving the quality. We achieved these projects, leading to an increase of our capacity to 180ton/day last year and to 215ton/day this year. Now we are planning to add another production line, mostly with a used machine, with the objective to produce 280ton/day.

papermiddleast 13

united all these lines together in one line deďŹ nitely this will reduce all the cost of electricity, energy, workers, etc. s $URING THE LAST MONTHS MANY PAPER MILLS IN %UROPE WERE CLOSED AND THE USED MACHINES WERE SOLD IN THE -IDDLE %AST JUST LIKE THE PAPER (OW DID YOU FACE THIS COMPETITION Actually the government charged high import taxes after the January revolution, which increased the local production of course. Also, on other hand, Egyptian traders only import grade no.3 of paper, which is considered as low quality compared to our national production. s -ANY PAPER MILLS ARE USING BAGGAS AS RAW MATERIAL )S THERE A RISK OF A SHORTAGE

s 3O FAR WHAT HAS BEEN THE IMPACT OF THE *ANUARY S REVOLUTION ON YOUR MILLS One of the biggest troubles we faced was the workersâ&#x20AC;&#x2122; demands to raise the salaries, which we did, but it affected the production cost as well. Also we faced another problem related to the energy cost due to the oil price raising. This problem should be solved next year, when we start using the natural gas in our mills. s (OW DO YOU EXPLAIN THAT IN %GYPT DESPITE THE LOWER LOCAL PRODUCTION COST SUCH AS SALARIES ENERGY RAW MATERIAL COMPARED TO MANY OTHER COUNTRIES THE lNAL PRICE SEEMS TO REMAIN HIGHER Mainly because they unite the production lines in one line only, this has a great effect in reducing the cost. For example, here in Misr Edfu we have two pulp production lines, two baggas production lines and three ďŹ ltering lines, if we 14 papermiddleast

There are many sugar mills in Egypt that burn baggas to use as a source of energy, and sure this will be changed after pumping the natural gas to these mills. When this happens they will have to ďŹ nd an alternative usage for this baggas, and using it in the paper industry is the most useful usage for it. By this, the baggas price will decrease a lot from now, and as a result it will reduce the paper production cost. In fact, many mills made studies to establish new mills from the baggas after pumping the natural gas.

s "EFORE WE CLOSE THIS INTERVIEW CAN YOU SHARE WITH US YOUR PERSONAL DREAMS My personal dreams are my general ones. I wish

to see Misr Edfu producing 80,000ton/year. And I wish to ďŹ nd a paper mill next to every sugar mill all over Egypt so we can produce 75% of the paper demand.

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Technology

Cutting through the foam, with minimum chemical cost By Mark Williamson, Journalist Engineer Online gas analyzers and closed-loop controls are helping to reduce the costs of de-foaming and de-aeration chemicals and eliminate quality and runnability problems associated with excess air and carbon dioxide bubbles. Investment payback periods are often just a few months.

aper, board and tissue making processes have become a lot more foamy in recent years, meaning that there is an excess of air mixed in from recycled furnishes and high turbulence papermaking processes and dissolved carbon dioxide gas released from calcium carbonate, now commonly used as a ﬁller and coating. Gas has become an unwanted and hard to control paper making ingredient. High foam levels in the wire pit or in overﬂowing chests are obvious symptoms. This foaminess can cause all sorts of troubles with the papermaking process resulting in pinholes, light spots, deposition problems on the sheet and on machine rolls and fabrics, and needless to say lost production due to web breaks and cleanups. Papermakers have responded by using more de-aeration de-foaming chemicals. However, the addition of chemicals is often uncontrolled since the root of the problem – the amount of free air and dissolved carbon dioxide Figure 1: BTG’s GAS-60 Gas Analyzer regularly samples the amount of free and dissolved gas in headbox flows and white water, allowing automatic control of chemicals.

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gas – is not precisely and regularly measured and gradual or sudden changes in gas levels are not recognized. As a result, the exact amount of chemical required at any time cannot be applied with any certainty and expensive overconsumption of chemicals is often the result. Moreover, the paper quality and runnability problems are not completely solved. However, there is an online automated solution that precisely controls the amount of residual air and gas in the furnish by applying just the right amount of chemical to minimize the impact of gas on the papermaking process. BTG has installed its GAS-60 Gas Analyzer (Figure 1) in a number of tissue, paper and board machines to regularly sample headbox ﬂows and white water and measure the amount of free and dissolved gas. Those frequently updated readings are used to automatically control the addition of chemicals. The result has been signiﬁcantly lower chemical consumption, less frequent sheet quality problems, fewer machine deposits and improved runnability. All told, some impressive ROI’s have been demonstrated.

Deﬁning the problems The magnitude of the gas content in a papermaking furnish and white water can be quite signiﬁcant. Figure 2 shows the volumetric composition of free and dissolved gas in a headbox

ﬂow. The volumetric gas fraction can exceed the ﬁber fraction.

Figure 2: The volumetric composition of free and dissolved gas is up to 5% in the headbox flow.

The gas in a papermaking furnish comprises two components which must be measured independently. Free gas (mainly air) is carried into the papermaking process through the stock preparation and deinking plants that use a ﬂotation process. Free gas is also mixed into the furnish at any point where there is high turbulence, typically in pumps, defective centricleaners or anywhere in the sheet forming process where water falls freely.

at a process pH below 8, dissolved carbon dioxide can be a problem as shown in Figure 3. Even at a neutral operating point dissolved carbon dioxide is signiﬁcant. Sometimes dissolved carbon dioxide can be created when a functional additive like a wet strength agent lowers the pH for a short period. When the headbox stock emerges from a high pressure area in the headbox to a much lower pressure area in the forming zone the large and sudden change causes the dissolved gas to be released as gas bubbles. These gas bubbles then burst on the wire, displace ﬁbers in the sheet and cause pinholes in low grammage sheets up to 60 g/m2 and light spots or cloudy formation on heavier grades. The surface charge and surface tension properties of gas bubbles can also cause poor drainage. This is particularly important on board machines where even drainage and ply moisture content is required for good bonding.

On the other hand, dissolved carbon dioxide gas is created by the dissolution of carbonate compounds found in hard water or, most signiﬁcantly, in commonly used calcium carbonate ﬁllers which are added to the furnish and paper coating. Broke that is re-circulated during break periods adds to the uncertainty of dissolved gas levels. Many papermaking processes run at an alkaline or neutral pH where carbonate dissolution is less than in an acid environment. Nevertheless,

Figure 3: Relative dissolved carbon dioxide levels as function of pH.

Figure 4: A dryer deposit caused by dissolved air being released as bubbles on the forming fabric.

Excess gas can also cause machine deposits on hydrophobic metal surfaces such as vats, piping, drying cylinders or rolls. Free air is often a problem before the headbox, causing vat foaming and metal surface deposits whereas deposits caused by dissolved gas are often apparent after the headbox and in the press and dryer sections. Figure 4 shows a dryer deposit caused by dissolved air being released as bubbles on the wire. Pinholes in a coating base sheet can cause strikethrough of the coating color and deposits on the coater backing roll. This can lead to sheet breaks and lost time to clean the roll. papermiddleast 17

Online analysis is the key De-foaming and de-aeration chemicals of course address many of these problems. However, operators cannot respond so quickly to changing needs brought on by a change in the furnish or broke recycle. Variations in ash levels, basis weight changes and dilution water can introduce air. If foaming persists there is always the tendency to add more chemical and leave it there just to be safe, even if it means a higher cost. Online measurements and controls have been the solution to this dilemma. BTG’s GAS-60 Gas Analyzer measures online both free air and dissolved gas by a sequential sampling and analysis technique. The principle shown in Figure 5 is simple and is based on Boyle’s gas law: P1V1 = P2V2. Boyle’s law states that, at constant temperature, the product of an ideal gas’s pressure and volume is always constant. In a papermaking stock only the air or carbon dioxide is compressible whereas the water and solid materials are not. Automatically controlled valves fill the analysis chamber with headbox stock or white water. An internal piston in the chamber is moved up and down from its initial position to change the chamber volume and compress the free air and then release the dissolved gas. The gas analyzer samples two points sequentially: typically the headbox flow and white water, then the control in a DCS system regulates the flow of chemical based on target values for

residual free or dissolved air where papermaking problems are eliminated. Which one is chosen for controlling the addition rate depends on the main objectives. If a reduction in pinholes is the goal, the dissolved gas of the headbox sample is controlled below a certain level. If the objective is to reduce the de-aerator or defoamer chemical costs the white water free gas reading is used for control with supervision by the headbox measurement. On machines with deculators it is possible to regulate de-aeration chemicals to reduce the loading on the deculator. In this way extra deculator capacity can be kept in reserve and the total cost of chemical and mechanical de-aeration can be minimized for a constant residual gas level.

Working together with chemical suppliers BTG has combined its measurement and control expertise with the chemical application knowhow of chemical suppliers to tackle foam control problems. One example is a large Southern USA linerboard mill with two machines. Operators habitually over-used chemicals to control foam. They knew that high wire pit foam was usually followed by sheet breaks and defects so their manual strategy was based on inspecting wire pit foam level. However, entrained air tests revealed the real problem was entrained air in the headbox. But no one knew when this condition would end so de-foamer was regularly added in excess of what was needed. A GAS-60 Gas Analyzer serving both machines was implemented and the operators were able to learn about and get used to the measurements and gradually reduce the chemical consumption. After implementing automatic closed-loop control in the DCS, the chemical consumption plummeted by 31.6% resulting in savings of hundreds of thousands of dollars per year and a handsome investment payback period of less than three months. See Figure 6.

Figure 5: Principle of measurement of the GAS-60 Gas Analyzer 18 papermiddleast

Figure 6: After implementing automatic closed-loop control of entrained air on two linerboard machines the chemical consumption plummeted by 31.6%, resulting in savings of hundreds of thousands of dollars and a handsome investment payback period of less than three months.

Results in newsprint and tissue Other BTG results in newsprint and tissue applications have been equally impressive. A 270,000 tpy newsprint machine suffered runnability problems from high free gas levels in the headbox that came from DIP furnish. After implementing closed loop control which reduced the gas content, the paper quality and runnability were better, retention and drainage were improved and the de-aeration chemical consumption was reduced by 60%. Altogether, the ROI was two months. In a tissue machine application the elimination of holes and associated web breaks was the primary target for gas control. Sheet holes were a problem during grade changes between grades containing wet strength resin and those containing none. The closed loop control was very successful, reducing free and dissolved air levels with the same chemical consumption. Holes and breaks were reduced, less broke was

Figure 7: With closed loop controls of free air in the silo, the chemical consumption on a newsprint machine was reduced significantly.

recorded during grade changes and the machine production was increased by two percent. The ROI was six months.

Sustaining the results For papermakers with chronic problems associated with foaming and high chemical consumption, a closed loop air control solution may be worth a look. The continuous measurements and controls are important to achieve and sustain the goals since the results of one-time tryouts are often short-lived. After short-term trials, the chemical addition rates often climb back to excess levels as papermaking conditions change. To date, more than 100 units have been installed in various papermaking applications. Gas analysis is ďŹ nding a new application in brownstock washing. Paper ďŹ rst published in the October issue 2012 of Pulp & Paper International (RISI)

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Food Packaging

:PSPJVUL *VH[PUNZ 6ăLY 5L^ 6WWVY[\UP[PLZ MVY -VVK *VU[HJ[ 7HWLY 7LYMVYTHUJL Kris Verschueren Christian Parein Dow Corning Europe S. A.

he food industry continues to evolve as a diverse and sophisticated entity, providing an expanding range of products in developed countries as well as emerging economies. Global consumers depend on packaging technologies to keep pace with innovation in the variety of food products available for an array of cultures. Meanwhile, food producers are creating distinctive ways to package food for preservation, shipping and storage.

years, now representing 81% of food release applications, and about 178,000 tons per year.(b ) Another family of papers designed for food contact is greaseproof and grease-resistant papers. Applications for this type of treated paper include the packaging and protection of all types of greasy food, including wet and dry products. Greaseproof and grease-resistant papers are commonly used with fresh food, fast foods and snack wraps, bagged and boxed items, pet food, microwave cooking products, margarine and butter, and bakery products.

Release Papers for Food Contact Two primary paper applications exist where food contact is required. The first is the general category of food release liners, where the major function of the paper is to perform with easy and clean release from the surface of processed food (Figure 1). Food release liners can be designed for single or multiple use, in professional applications or for the home market. Reusable baking papers, interleaves or single-use papers fall into this category. The range of uses for release liners in general has led to a significant global market: in 2010, total global release liner production was approximately 2.40 million tons.(a) In the food industry alone, use of silicone-coated paper for food applications has doubled in less than five 20 papermiddleast

Figure 1. Use of silicone-coated paper continues to grow in the food industry.

ow Corning, formed in 1943 as a joint venture between The Dow Chemical Company and Corning Incorporated, provides performance-enhancing solutions to serve the diverse needs of more than 25,000 customers worldwide. A global leader in silicones, silicon-based technology and innovation, Dow Corning offers more than 7,000 products and services via the company’s Dow Corning® and XIAMETER® brands.

Greater Opportunity for Silicone In addition to their broad use in food release liners, silicone coatings hold potential for use in greaseproof or grease-resistant papers. The majority of materials used for greaseproof packaging are plastic-based, where primary applications are in the fresh, fast-food and pet food markets. Only 26% are paper-based, and of that segment, only 43% represents chemicallytreated paper, including use of waxes and ﬂuorochemicals.(c) Although plastic-based applications are growing twice as fast as those using paper, recyclability is increasingly viewed as important by consumers. This preference indicates is a primary advantage of paper and board. (a) The Future of Specialty Papers to 2015, Pira International Ltd. (2010). (b) Specialty Papers and Paperboards Global Sourcebook, Alexander Watson Associates (2010) and Dow Corning data. (c) Dow Corning data

In recent years, several market trends have influenced the growth of various food contact papers. In addition to economic drivers the food contact segment has been driven by environmental considerations, both on the part of manufacturers and consumers. Due to concerns over toxicity related to incineration, the market has shifted away from heavy metal-based paper coatings such as chromium, which was broadly used in the bakery paper segment. Meanwhile, interest also has increased with regard to monitoring long-term exposure to perfluoroalkylated substances because of suggested health risks. Several initiatives have encouraged reduction in the use of fluorine-based substances on a voluntary basis. Although systems based on the use of fluorochemicals have been dominant in the greaseresistant paper markets for many years, other options are available and are likely to become more common if resistance to the use of fluorochemicals increases further. Some industrial

Figure 2. A siliconization step can easily be integrated at the end of the paper manufacturing process. Figure courtesy of Dow Corning. papermiddleast 21

users have already replaced ﬂuorochemicals, while others have announced their intent to do so in the future. Even recycling issues with wax-coated paper have come to the fore. Because the waxes used are not biodegradable, additional chemistry is required in terms of wetting agents and dispersants to prevent buildup of deposits over time. Economic drivers include growth of the fast food and processed food segments, along with the demand for greater speed. These changes are triggered by urbanization, shifts in eating habits and a changing and growing population. Responding to these differences has become in part an ease-of-use approach, where greater use of food contact paper leads to greater efﬁciency. For example, with the use of food contact papers, cleaning may not be required on surfaces that were in contact with food after its heating or baking. Trends of this type continue to drive changes in the coated paper industry. Silicone coatings for bakery papers are becoming more popular,

Figure 3. Cross-section of silicone-coated paper. Red line indicates paper surface with coating. Photo courtesy of Dow Corning. 22 papermiddleast

particularly in the EU, where greater than 90% of the market has switched. In contrast, only a minority of the American market has made the change, due in part to less demanding requirements in terms of release and greater popularity of single-use papers. The change to silicone-coated paper does not necessarily lead to an increase in cost of use because of factors such as coat weight reduction and better performance. An increasing focus on sustainability, including recyclable liners, renewable materials, and energy consumption efficiencies also is driving the market toward great use of silicone-coated papers. Geographic expansion, primarily driven by developing markets in India, China and South America, has led to an increase in food processing, with resulting greater demand for performance and cost efficiency in food contact paper. In developed countries, a reduction in average household size (due to more single-person households or singleparent families) has resulted in more individual households and greater use of packaging. In summary, there are several drivers for change in the food contact paper segment. The search for higher product value by paper mills encourages the development of valueadded products. In response, the success of a new product will be determined not only by its cost in relation to barrier performance, but also by its ease of application (i.e., low equipment cost) and compatibility with existing converting processes—or the ability to use new technologies on existing equipment. Predictability and consistency of performance are linked to any potential advances. The case for environmental responsibility and renewability argues against wax and film barriers, while opening the door to more high performance materials. A growing sense of corporate social responsibility in terms of sustainability, renewability, recyclability, and waste management—in short, a stronger concept of cradle-to-grave responsibility—can alter the entire continuum of manufacturing, waste disposal, and recycling.

Silicone Emulsion Technology in the Marketplace Silicone coating technologies have a long history, and with time, they have become more appropriate for food applications. The ﬁrst, and oldest, technology is solventbased coating, which depends on using a solvent as a carrier to deposit silicone on the paper substrate. This approach is no longer a preferred method, and is gradually being phased out of use due to safety concerns associated with some solvents. Another method, solventless coating, is primarily used in labeling applications. Emulsion technology is the preferred coating method for a variety of applications including food contact. This technique is based on a platinum-catalyzed reactive system. This method produces low levels of byproduct and is in fact commonly used for curing silicone for medical applications, where safety and purity are sensitive issues. In release coating applications such as food and labels, the water-based silicone coating system consists of two reactive parts that are combined and mixed just before application. Part A of the emulsion coating contains the polymer and a cross-linker. Part B contains the platinum catalyst diluted in a polymer for easy handling. Application of the silicone emulsion is easy and can be done online as part of the paper manufacturing process, eliminating the need for a separate process by a converter. As part of the online process, the reactive silicone emulsion is applied to the paper before the last drying step, and the silicone is dried and cured in the ﬁnal process stage (Figure 2).

for use in greaseproof applications. For food release, key characteristics of silicone are its outstanding release properties, without sticking. Silicone coated paper has a low Cobb60 value of approximately 8 to 15 g/m2, which indicates a high resistance to absorbing water. A low value of this type is primarily important for frozen food processing. Greaseproof paper requires good resistance to grease over time, also important for packaging. A silicone-modiﬁed coating can give a Kit test value up to 12.

Conclusions The food contact segment of the industry is a high growth market segment, driven by economics, changing populations, technology advances and environmental concerns. Silicone release papers are primarily used for bakery and food release operations, and market penetration of the silicone application is growing. The appropriate silicone technology for producing greaseproof papers is established and holds promise for the food industry, with the added beneﬁt that silicones already comply with requirements for food-contact applications. Given the success of silicone technology for release papers, considerable opportunity exists for technology transfer to greaseproof applications and further penetration into the packaging market. Dow Corning invites your interest in exploring options that would serve your needs. For more information, contact your local Dow Corning representative.

Paper coated with as little as 0.30 g/m2 silicone offers outstanding release properties and multiple uses. The resulting waterproof material is microwavable, repulpable and compostable. Figure 3 shows a cross-section of such a paper. Several properties of siliconized paper make it useful for food contact and also show potential papermiddleast 23

Events >> Report Paper Arabia 2012

Online gas analyzers and closed-loop controls are helping to reduce the costs of de-foaming and de-aeration chemicals and eliminate quality and runnability problems associated with excess air and carbon dioxide bubbles. Investment payback periods are often just a few months.

Paper Arabia 2012 concludes with 90 % bookings for next edition

aper industry in Dubai resembles the situation paper industry was in Singapore eight years ago, as it is becoming a regional trade hub for paper and tissues, according to statement conducted by major participant at Paper Arabia 2012, the ﬁrst-of-its-kind industry expo at the Dubai International Exhibition and Convention Centre which concludedon October 3, 2012.

The event attracted over 7,200 trade visitors, an increase of 10 per cent over last year. The visitors came from 70 countries and more than 90 percent of the display area has already been booked for next year’s edition, according to Satish Khanna, General Manager, Al Fajer Information and Services, organizers of the show. Paper Arabia sent a clear message to industry 24 papermiddleast

players that environmental standards in the paper industry are going up, policies are becoming stricter and the demand for eco friendly products is on the rise. The next edition of Paper Arabia will be held from 29th September to 1 October 2013.

The ﬁfth edition of Paper Arabia was a huge success. Companies’ stands were buzzing with enthusiastic visitors from all over the region. Leading paper manufacturers found the opportunity to meet face to face. The increased number of Chinese and Indian suppliers sent out the signal that the center of gravity within paper industry has shifted eastward. Industry expert says: “USA and Europe are no longer the dominant forces in paper industry. Asian companies are setting the standards in productivity and in diversifying paper products. Environmental

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issues also are becoming more relevant and more important in our region.”

our packaging sales grew by almost 30%. Growth in stationery is stable, while the writing and printing paper segment has grown by over 10%.” Khanna said: “Paper Arabia offered through three days opportunities to manufacturers and suppliers of ﬁnished products, equipment, machinery, paper chemicals, services, supplies of paper, tissue and converting sector to tap the Middle East and North African markets. The show placed special emphasis on hygiene and disposable products, reﬂected in the demand for various products such as wet wipes, baby diapers and sanitary napkins.”

Mr. Suresh Kilam, of the Indonesian Pulp and Paper Association, one of the world’s biggest associations specializing in paper and Executive Director, Asia Pulp & Paper (APP), world’s second largest pulp and paper producing company and the largest vertically integrated pulp and paper producer in Asia, excluding Japan, said that UAE’s paper industry resembles to a large extent Singapore’s paper industry eight years ago and the country has great potential to be a trade hub for paper and tissues. Suneet Sood, CEO of APP Dubai, added: “As a paper manufacturer in the Middle East, we need to showcase our products in an exhibition/trade fair and Paper Arabia is a good forum for paper manufacturers like us to participate. It’s an opportunity for us to meet our customers. We saw customers coming from Iran, Kuwait and other GCC countries.” Talking about the popular paper varieties in the Middle East, Suneet said, “The writing and printing paper is of a major grade sold by us. This constitutes about 50% of our sales. In writing/printing we cover the uncoated wood free and the coated wood free. The second segment is packaging. Though the packaging sector is comparatively small for us, the growth is high in this sector. Last year, 26 papermiddleast

Manufacturers, converters, distributors and traders from all over the world visited Paper Arabia 2012 to grow business and share expertise. Khanna added: “The UAE has certainly emerged as a leader in the re-export of paper and is making progress in producing paper. After talking with major paper industry players who participated at the show, we are upbeat about the industry which we think has great potential for further growth. Dubai has an instrumental role to play in the paper industry. Many high tech and heavy duty machines from China were sold at the three day show to companies from the region.” Khanna added: “Asia and India are becoming major suppliers of paper to the UAE and the region. They have taken a front seat against Europe and Unites States due to the Dollar-Euro ﬂuctuation.

We have felt dominant Asian participation at the show and these companies are willing to put more investments in the region through opening up headquarters in Dubai.”

ming more important and a must-attend event to participate and to visit. “It has evolved to become one of the most important paper industry events in the world,” said Bakht.

Sunil Bakht, Chairman of Orient Links was upbeat about the show. He said: “I think speciﬁc buyers and the decision makers are here. The quality of the visitors is very high. We had visitors from entire GCC as well as Nigeria, Kenya, Iran and Syria.”

Talking about his company’s plans, Bakht added: “Packaging is growing very fast and we have to be part of this lucrative market. We are setting up a new division dedicated to packaging. At the moment we are selling more than 200,000 tons of writing and printing grade paper. But in the near future packaging boards will also be part of our offering.”

Bakht also believes that Paper Arabia is beco-

Events >> Paper Middle East 2012

The three day exhibition had witnessed an unexpected success that had surpassed all expectations

APER-ME2012 took place between 8th – 10th of November, 2012 at Cairo International The exhibition has witnessed the participation of more than 190 companies aside from the group participation coming from more than 28 countries : Germany, China, India, Italy, Finland, Chez Republic, Sweden, Austria, Greece, Taiwan, France, Malaysia, Korea, South Korea, Serbia, Thailand, Spain, Turkey, Lebanon, Saudi Arabia, Tunisia, Syria, United Arab Emirates, in addition to many Egyptian factories. The exhibition attracted more than 9000 visitors representing the key player companies who were interested in the exhibition’s sectors.

better they were able to clinch deals during and after the show. The exhibition this year had featured an outstanding showcasing of the latest products, equipment and the paper manufacture machinery, cardboard, tissue, paper , printing technology and packaging. The exhibitors expressed great admiration to the outstanding level of visitors and the opportunity presented by the exhibition to reach one of the most important markets in the world. PAPER-ME2012 was under the patronage of various prestigious institutions including the Ministry of Trade and Industry, The Council of Arab unity, The Economic Arab Union Paper Industries and packaging ending with the Export Council for Chemical Industries, which have played an affective role in supporting the exhibition in order to reach these industries to compete with global products and increase exports. The event closed on a highly successful note MARK YOUR CALENDAR FOR PAPER-ME 2013, 7TH – 9TH OF NOVEMBER 2013

PAPER-ME2012 was sponsored by Asia Pulp and Paper (APP), the 2nd largest paper manufacturer and supplier and Asia’s number one paper manufacturer and supplier Participating in Paper ME 2012 enabled exhibitors to effectively achieve their main objectives, such as widening their business network, meeting decision – makers and attracting new customers, even 28 papermiddleast

Exhibitors’ statistics

The show attracted 188 exhibitors, including 44% of international participants. A 39% increase from last year’s edition.

Visitors’ statistics With nearly 10 000 visitors from 42 countries, and a very high satisfaction rate, the 2012 Paper ME exhibition has the best show ever according to organizers.

papermiddleast 29

30 papermiddleast

Events

Bellmer Paper Days An instructive and pleasant international gathering organized by the German manufacturer of paper machinery.

round 150 people from 18 countries gathered last November for the Bellmer Paper Days in Niefern (Germany), the home town of the company. And this year was quite a special edition. Clients who accepted to join the event were invited to present a series of projects successfully conducted. Among them was Mr. Pedro Huerta, CEO of the Surpapel Group based in Chile, who described how Bellmer moved and installed a complete production line from Italy to Ecuador. Another interesting presentation was how Komabassan Kagit in Turkey, represented by its General Manager, Mr. Mehmet Eray Nasöz, achieved the challenge to reduce by 80% the number of ruptures on its machine with the Help of Bellmer engineers. The audience was also impressed by stories told by clients from Germany obviously, but also Austria, Poland, France, Russia, India and China, all related to their concern of operating a machine in the most economical way. The Bellmer know-how in this field seems to have been very efficient. Presentations were punctuated by social times making possible discussions between papermakers from the world over. Culture and fun were also part of the programme, with good food, young talents playing jazz or dancing, and a bluffing magician.

32 papermiddleast

This event was also an opportunity to celebrate the 170th anniversary of the company, and to inaugurate its brand new 5,000 sq m facility, located in the neighboring city of Enzberg, built on a former football ground. The new plant, with state-of-the-art equipment, allows Bellmer to improve the assembly of its paper machines, expanding its manufacturing capacity up to 8m of width. The integration of the roller production, previously sub-contracted, is also made possible. It is, of course, a locally-made Bellmer sparkling wine that was used for the baptism ceremony.

Events

Tissue World 2013 in Barcelona cated with only about 300-400 square meters remaining on the ﬂoor plan.

Excellent learning opportunity

xcitement is now building for Tissue World 2013, the world’s largest event targeted specifically at the soft hygienic tissue paper business. This is the first time that Tissue World will be held in Barcelona, after moving from Nice where it has been since it started in 1993. The tissue industry has shown strong support for the move. Top-level speakers, tissue makers and converters from around the globe, and most of the world’s suppliers to the tissue business, are all keen to be part of the event. Luigi Lazzareschi, CEO of the Sofidel Group based in Lucca, Italy, will be among the speakers at the opening management/markets session of the Tissue World Conference on Monday 18 March. Sofidel, which recently surpassed the milestone of one million tons per year of annual capacity, is Europe’s number two tissue producer and number six in the world. It has undergone very dynamic growth throughout Europe over the past two decades and is now also entering the US market. Numerous other companies and organizations such as SCA, WWF, RISI and the European Tissue Symposium have also agreed to be on the Day One management and markets session. Other speakers will of course be joining this session.

Floor space is 90% ﬁlled By late November, four months before the show opens, around 130 companies from all over the world have booked stand space at the event. Many exhibitors are joining the show for the ﬁrst time. In terms of net space this means about 3,700 square meters have been booked, very close to the total size of the most recent Tissue World 2011 in Nice. The space is now over 90% allo-

Tissue World isn’t just a show. It’s an experience for all tissue makers and converters looking for new ideas, new technology, new ways of doing things, and new approaches to improve their business. By getting out of their day-to-day routine, visitors to Tissue World ﬁnd new stimulation and inspiration to help them do their jobs better. This can include both meeting daily operational challenges, as well as assisting in developing longer-term corporate and product strategies. The combination of the exhibition of suppliers, with the management/market sessions and the technical sessions, as well as the Yankee dryer workshop, give tissue makers and converters everything in one event.

Good for planet, and proﬁts The theme of the conference for 2013 is ”Evolution or Revolution: The Next Steps in Sustainable Tissue Making.” Many companies in the tissue industry are today taking giant steps to become even more sustainable. What is good for the environment is often good for the bottom line as well. Clearly, the critical inputs for tissue making, such as ﬁbers, energy and water, are becoming more scarce and expensive raw materials. At the same time, many environmental groups, retailers and consumers are focusing on the tissue industry and the responsible use of these raw materials. Savings all through the supply chain can mean reduced environmental impact, as well as reduced costs. Tissue World is a great place to gather more information on all of these aspects of sustainable tissue making. Thus, despite some initial hesitation about the move to Barcelona, the event is developing very nicely and will once again be the focal point for the world’s tissue business next March. The dates of the event are 18-21 March for the conference meeting sessions, and 19-21 March for the trade show of vendors. For more information, please visit www.tissueworld.com. papermiddleast 33

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