TECHNICAL FIELD

[0001] The present disclosure relates to the field of manufacture of liquid packaging board.

BACKGROUND

[0002] Liquid packaging board (LPB) is an engineered material that often consists of different layers and interfaces. This generates an out-of-plane (z) profile that can be designed for optimal functionality or cost performance. Commercial LPB often has a relatively bulky middle ply to obtain high bending stiffness with a low amount of fibers.

[0003] Creasing and subsequent folding is necessary to convert LPB into packages. In the creasing operation, a male ruler is pressed against the board, which is positioned on top of a female die. The purpose of the creasing operation is to facilitate subsequent folding. During folding and forming, there is however a risk of cracking.

SUMMARY

[0004] An objective of the present disclosure is to provide for reduced cracking tendency of LPB during folding and forming.

[0005] Accordingly, the present disclosure provides a method of producing a multi-layered liquid packaging board (LPB) comprising a print layer, a back layer and a middle layer, said method comprising the steps of:

- providing a chemithermomechanical pulp (CTMP) and forming a middle layer furnish comprising the CTMP and hydrophobic size;

- forming a middle layer web from the middle layer furnish in a forming section of a full-scale paperboard machine;

- forming a print layer web from a print layer furnish in the forming section, which print layer furnish comprises hydrophobic size;

- forming a back layer web from a back layer furnish in the forming section, which print layer furnish comprises hydrophobic size;

- merging the print layer web to the middle layer web by couching, preferably at a couching dryness above 10%, such as above 13%, wherein the z strength of the CTMP is at least 150 kPa, such as at least 180 kPa, when measured according to ISO 15754:2009 after sheet forming according to ISO 5269-2:2004.

BRIEF DESCRIPTION OF THE DRAWINGS

[0006] Fig. 1 shows results from testing of samples obtained from a machine trial carried out during production of a 290 g/m ² three-layered (non-LPB) board having a middle layer formed from a furnish comprising 45% CTMP, 45% broke and 10% kraft pulp. During one period of the trial, the amount of spray starch applied in the print layer/middle layer interface was 0.83 g/m ² . During another period of the trial, the amount of spray starch applied in the print layer/middle layer interface was 1.05 g/m ² . For each amount, Fig. 1 shows the proportion of samples in which the failure occurred in:

(i) the print layer/middle layer interface (“PL interface”);

(ii) the middle layer (“ML”);

(iii) the back layer/middle layer interface (“BL interface”); and

(iv) both interfaces (“Double del.”).

[0007] Fig. 2 shows results of Scott Bond tests on samples obtained from the Reference trial (n=5o) and the Inventive trial (n=25). In detail, Fig. 2 presents the point of failure, i.e. where in the z direction the board broke during Scott Bond testing, for each tested sample. The abbreviations used in Fig. 2 are explained above with reference to Fig. 1.

[0008] Fig. 3 shows the shear strength profiles across the z direction of boards produced in the high dryness run and the low dryness run. The abbreviations used in Fig. 3 are explained above with reference to Fig. 1.

DETAILED DESCRIPTION

[0009] The present disclosure provides a method of producing a multi-layered liquid packaging board (LPB) comprising a print layer, a back layer and a middle layer. As understood by the skilled person, the middle layer is arranged between the print layer and the back layer.

[0010] The method comprises the steps of:

- providing a CTMP and forming a middle layer furnish comprising the CTMP and hydrophobic size;

- forming a middle layer web from the middle layer furnish in a forming section of a full-scale paperboard machine;

- forming a print layer web from a print layer furnish in the forming section, which print layer furnish comprises hydrophobic size; and

- forming a back layer web from a back layer furnish in the forming section, which print layer furnish comprises hydrophobic size.

[oon] The presence of hydrophobic size in each of the above-mentioned furnishes is typical for a method of manufacturing LPB.

[0012] The amount of hydrophobic size in each of the print layer furnish and the back layer furnish is preferably at least 1.5 kg/tonne dry fibre, such as at least 2.0 kg/ tonne dry fibre.

[0013] The amount of hydrophobic size in the middle layer furnish is typically greater than in any of the print layer furnish and the back layer furnish. As an example, it maybe at least 2.5 kg/tonne dry fibre, such as at least 3.0 kg/tonne dry fibre.

[0014] The hydrophobic size in each of the print layer furnish, the back layer furnish and the middle layer furnish may for example be independently selected from the group consisting of alkenyl succinic anhydride (ASA), alkyl ketene dimer (AKD), rosin size and combinations thereof. In a preferred embodiment, the hydrophobic size in each of the furnishes is a combination of AKD and rosin size. When such a combination is used, the headbox pH of the furnishes is preferably in the range of 6.6-y.2, such as 6.9-7.1.

[0015] The print layer web is merged with the middle layer web by couching. This is preferably done at a couching dryness above 10% (preferably above 13%) in order to reduce the strength of the interface between the print layer and the middle layer and thereby avoid delamination in the middle layer during folding. Here, couching dryness refers to the dryness of the print layer web at the point of couching. In one embodiment, the print layer web and the middle layer web both have a dryness above 10%, such as above 13%, at the point of couching.

[0016] Preferably, the back layer web is also merged with the middle layer web by couching at a couching dryness above 10% (preferably above 13%) in order to reduce the strength of the interface between the back layer and the middle layer. Here, couching dryness refers to the dryness of the back layer web at the point of couching. In one embodiment, the back layer web and the middle layer web both have a dryness above 10%, such as above 13%, at the point of couching.

[0017] The z-directional tensile strength (“z strength”) of the CTMP is at least 150 kPa, such as at least 180 kPa, when measured according to ISO 15754:2009 after sheet forming according to ISO 5269-2:2004 (a suitable upper limit of this z strength maybe 250 kPa). Thereby, the risk of delamination within the middle layer (and hence the risk of cracking, see below) is reduced. For the same reason, the tensile index of the CTMP is preferably above 15 Nm/g, such as above 17 Nm/g, when measured according to ISO 1924-3:2005 after sheet forming according to ISO 5269- 1:2005. A Rapid-Kothen automatic sheet forming machine is preferably used for said sheet forming according to ISO 5269-1:2005. “Tensile index” is the tensile strength obtained by ISO 1924:3:2005 divided by the grammage. Grammage is measured according to ISO 536:2019. The z strength of a CTMP can be increased by refining the CTMP.

[0018] In one embodiment, the CSF of the CTMP of the middle layer furnish is below 600 ml, such as 500-580 ml, when measured according to ISO 5267-2:2001. Such a relatively low CSF value is associated with a favorable middle layer strength to interface strength ratio in the z direction.

[0019] To achieve bulk, the proportion of CTMP in the middle layer furnish is preferably above 20% by dry weight, such as above 30% by dry weight, such as at least 32% by dry weight. In some embodiments, it may be preferred to keep the proportion of CTMP in the middle layer furnish below 45% (e.g. 42% or lower) to in order to prevent the Scott Bond value from being too low. Accordingly, the proportion of CTMP in the middle layer furnish may be within any of the following ranges: above 20%, but below 45%; above 20%, but no more than 42%; above 30%, but below 45%; above 30%, but no more than 42%; at least 32%, but below 45%; or at least 32%, but no more than 42%.

[0020] In addition to the CTMP, the middle layer furnish preferably comprises broke pulp. The broke pulp maybe obtained from the LPB production that the method of the present disclosure forms part of. The proportion of broke pulp in the middle layer furnish is typically in the range of io%-5O%, preferably io%-35%, more preferably 2O%-33%.

[0021] Further, the middle layer furnish preferably comprises chemical pulp, such as kraft pulp, preferably softwood kraft pulp. This chemical pulp maybe bleached or unbleached. A particularly preferred type of chemical pulp is bleached softwood kraft pulp. The proportion of chemical pulp in the middle layer furnish is typically in the range of io%-5O%, such as 20%-40%. One reason for including chemical pulp (preferably softwood kraft pulp), which is relatively strong type of pulp, is to balance the CTMP, which is a relatively weak type of pulp.

[0022] A suitable Schopper-Riegler (SR) number for the middle layer furnish is °I8-°23. Such a SR number may be obtained by adapting the degree of refining of the respective pulps forming the middle layer furnish. The SR number is measured according to ISO 5267-1:1999.

[0023] The z strength of the middle layer furnish is preferably at least 375 kPa, such as at least 415 kPa, when measured according to ISO 15754:2009 after sheet forming according to ISO 5269-2:2004. A suitable upper limit is 545 kPa, such as 495 kPa.

[0024] In one embodiment, the provided CTMP is obtained by post-refining CTMP from a CTMP production process. As understood, such post-refining is carried out in the wet end of the LPB production process. However, the degree of postrefining is preferably low, e.g. below 30 kWh/ tonne dry fibre.

[0025] In a machine trial carried out during production of a 290 g/m ² threelayered (non-LPB) board having a middle formed from a furnish comprising 45% CTMP, 45% broke and 10% kraft pulp, it was shown that an increase of the amount of spray starch applied in the print layer/middle layer interface from 0.83 g/m ² to 1.05 g/m ² resulted in that the proportion of failures during Scott Bond testing in this interface was reduced from 100% to about 45% (see Fig. 1). Hence, in one embodiment of the method, less than 1 g/m ² , such as less than 0.9 g/m ² of starch is provided in the interface between the print layer web and the middle layer web. Consequently, in one embodiment of the method, no starch is provided in the interface between the print layer web and the middle layer web. Alternatively, more than 0.2 g/m ² , such as more than 0.3 g/m ² of starch is provided in the interface between the print layer web and the middle layer web. Consequently, in one embodiment, less than i g/m ² and more than 0.2 g/m ² of starch, such as less than 0.9 g/m ² and more than 0.3 g/m ² of starch, is provided in the interface between the print layer web and the middle layer web. For the avoidance of doubt, this does not include starch added to any of the furnishes upstream the headboxes.

[0026] Further, less than 1 g/m ² , such as less than 0.9 g/m ² of starch maybe provided in the interface between the back layer web and the middle layer web. Consequently, in one embodiment of the method, no starch is provided in the interface between the print layer web and the middle layer web. For the avoidance of doubt, this does not include starch added to any of the furnishes upstream the headboxes.

[0027] The method may comprise the step of coating the print layer with at least one coating layer. The at least one coating layer is typically pigment -based. The total coat weight (dry) maybe 12-30 g/m ² .

[0028] The basis weight of the multi-layered LPB produced by the method (including any pigment-based coating) may for example be 150-350 g/m ² , preferably 210-310 g/m ² . The basis weight of the print layer (excluding any pigment-based coating) maybe 45-90 g/m ² , such as 55-80 g/m ² . The basis weight of the back layer maybe 40-70 g/m ² , such as 40-65 g/m ² . Basis weight (also referred to as grammage) is measured according to ISO 536:2019.

[0029] The density of the multi-layered LPB produced by the method may for example be 650-750 g/m ² . Density is measured according to ISO 534:2011.

[0030] The z strength of the multi-layered LPB produced by the method may for example be 280-415 kPa, such as 300-400 kPa. z strength is measured according to ISO 15754:2009.

[0031] The Scott Bond strength of the multi-layered LPB produced by the method may for example be 145-305, such as 170-250 kPa. Scott Bond strength is measured according to TAPPI T 569 om-09. EXAMPLES

Reference trial

[0032] A three-layered liquid packaging board (LPB) was produced in a full-scale paperboard machine. The layer design of the LPB was as follows: a bleached print layer (65 g/m ² ), an unbleached back layer (60 g/m ² ), a middle layer (125 g/m ² ) and a pigment coating (19 g/m ² ) applied onto the print layer.

[0033] To prepare a print layer furnish, bleached hardwood kraft pulp (NBHK) and bleached softwood kraft pulp (NBSK) were mixed in a 60:40 dry weight ratio. Before the mixing, the NBHK and the NBSK were subjected to LC refining (65 and 150 kWh/ tonne, respectively) such that both pulps obtained an °SR value of about 32. Before the print layer headbox, rosin size (1.5 kg/tonne), AKD (1 kg/tonne), alum (2.3 kg/tonne), strength agent (cationic starch, 2.5 kg/tonne), retention starch (3 kg/tonne), retention polymer (100 g/tonne) and silica (300 g/tonne) were added. In the print layer headbox, the consistency was 0.19% and the pH was 6.8.

[0034] A back layer furnish was prepared from unbleached softwood kraft pulp

(UBK) that had been subjected to LC refining (100 kWh/ tonne) to obtain a °SR value of about 23. Before the back layer headbox, rosin size (1.5 kg/tonne), AKD (1 kg/tonne), alum (1.5 kg/tonne), strength agent (cationic starch, 2.5 kg/tonne), retention starch (3 kg/tonne), retention polymer (100 g/tonne) and silica

(300 g/tonne) were added. In the bottom layer headbox, the consistency was 0.18% and the pH was 6.8.

[0035] To prepare a middle layer furnish, broke pulp, NBSK and CTMP were used in a 30:35:35 dry weight ratio. The CTMP had a tensile index of about 13-14 Nm/g (when measured according to ISO 1924-3 after sheet forming according to ISO 5269- 1:2005). Before mixing, the pulps were subjected to LC refining to obtain the following values: about °SR 30 for the broke pulp (refining energy: about 20 kWh/tonne); about °SR 23 for the NBSK (refining energy: about 100 kWh/tonne) and about CSF 550 ml for the CTMP (refining energy: about 20 kWh/tonne). Before the middle layer headbox, rosin size (2.5 kg/tonne), AKD (2.5 kg/tonne), alum (3.8 kg/tonne), strength agent (cationic starch, 2.5 kg/tonne), retention starch (3 kg/tonne), retention polymer (100 g/tonne) and silica (300 g/tonne) were added. In the middle layer headbox, the consistency was 0.41% and the pH was 6.8. The wire used for forming the middle layer included e.g. a top former and a breast roll shaker.

[0036] In the wire section (wire speed = 623 m/min), starch (0.7 g/m ² ) was sprayed to each of the print layer web and the back layer web. At the end of the wire section, the three individual webs (with the starch-sprayed side of the outer webs facing the middle web) were couched together to form a three-layered web. At the couching stage, the dry matter content of each web was about 14%-16%. In the press section arranged downstream the wire section, the three-layered web was pressed in three nips; a first double-felted shoe press nip (450 kN/m) followed by a second double-felted shoe press nip (600 kN/m) and a hard nip (50 kN/m).

[0037] Downstream the press section, the three-layered web was dried in a drying section and then calendered in a hard nip calender at a line load of 20 kN/m and a temperature of 24O°C. After the calendering, the web was coated in a coating section having several coating stations. In a blade coating station, 7.5 g/m ² of a pigment coating composition was coated onto the surface of the print layer. In another station, which was a metering size press (MSP), a small amount (0.4 g/m ² ) of starch was coated onto the back surface. In a second blade coating station, another 11.5 g/m ² of a pigment coating composition was coated onto the top surface. Hence a total of 19 g/m ² was coated onto the print surface and a total of 0.4 g/m ² was coated onto the back surface.

Inventive trial

[0038] A three-layered liquid packaging board (LPB) was produced in a full-scale paperboard machine. The layer design of the LPB was as follows: a bleached print layer (65 g/m ² ), an unbleached back layer (50 g/m ² ), a middle layer (125 g/m ² ) and a pigment coating (19 g/m ² ) applied onto the print layer.

[0039] To prepare a print layer furnish, bleached hardwood kraft pulp (NBHK) and bleached softwood kraft pulp (NBSK) were mixed in a 30:70 dry weight ratio. Before the mixing, the NBHK and the NBSK were subjected to LC refining (50 and 120 kWh/ tonne, respectively) such that both pulps obtained °SR values of 28 and 25, respectively. Before the print layer headbox, rosin size (1.5 kg/tonne), AKD (1.5 kg/tonne), alum (2.3 kg/tonne), strength agent (cationic starch, 2.5 kg/tonne), retention starch (3 kg/tonne), retention polymer (50 g/tonne) and silica (150 g/tonne) were added. In the print layer headbox, the consistency was 0.19% and the pH was 7.0.

[0040] A back layer furnish was prepared from unbleached softwood kraft pulp

(UBK) that had been subjected to LC refining (100 kWh/tonne) to obtain a °SR value of about 23. Before the back layer headbox, rosin size (1.5 kg/tonne), AKD (1 kg/tonne), alum (1.5 kg/tonne), strength agent (cationic starch, 2.5 kg/tonne), retention starch (3 kg/tonne), retention polymer (100 g/tonne) and silica (300 g/tonne) were added. In the bottom layer headbox, the consistency was 0.18% and the pH was 7.0.

[0041] To prepare a middle layer furnish, broke pulp, NBSK and CTMP were used in a 30:35:35 dry weight ratio. The CTMP had a tensile index of about 18-19 Nm/g (when measured according to ISO 1924-3 after sheet forming according to

ISO 5269-1:2005). Before mixing, the pulps were subjected to LC refining to obtain the following values: about °SR 30 for the broke pulp (refining energy: about 10-20 kWh/tonne); about °SR 23 for the NBSK (refining energy: about 100 kWh/tonne) and about CSF 560-565 ml for the CTMP (refining energy: about 10-20 kWh/tonne). Approximative properties of the refined CTMP and the furnish (containing all three pulps) are provided in table 1 below. Before the middle layer headbox, rosin size (2.5 kg/tonne), AKD (2.5 kg/tonne), alum (3.8 kg/tonne), strength agent (cationic starch, 1 kg/tonne), retention starch (3 kg/tonne), retention polymer (75 g/tonne) and silica (225 g/tonne) were added. In the middle layer headbox, the consistency was 0.37% and the pH was 7.0. The wire used for forming the middle layer included e.g. a top former and a breast roll shaker.

[0042] Table 1. Approximative properties of refined CTMP and middle layer furnish, measured after sheet forming according to ISO 5269- 2:2004.

[0043] In the wire section (wire speed = 623 m/min), starch (0.7 g/m ² ) was sprayed to each of the print layer web and the back layer web. At the end of the wire section, the three individual webs (with the starch-sprayed side of the outer webs facing the middle web) were couched together to form a three-layered web. At the couching stage, the dry matter content of each web was about 14%-16%. In the press section arranged downstream the wire section, the three-layered web was pressed in three nips; a first double-felted shoe press nip (390 kN/m) followed by a second double-felted shoe press nip (460 kN/m) and a hard nip (50 kN/m).

[0044] Downstream the press section, the three-layered web was dried in a drying section and then calendered in a hard nip calender at a line load of 20 kN/m and a temperature of 240°C. After the calendering, the web was coated in a coating section having several coating stations. In a blade coating station, 7.5 g/m ² of a pigment coating composition was coated onto the surface of the print layer. In another station, which was a metering size press (MSP), a small amount (0.4 g/m ² ) of starch was coated onto the back surface. In a second blade coating station, another 11.5 g/m ² of a pigment coating composition was coated onto the top surface. Hence a total of 19 g/m ² was coated onto the print surface and a total of 0.4 g/m ² was coated onto the back surface.

Evaluation

[0045] LPB produced in the Reference trial and the Inventive trial was tested according to the Scott bond method. However, the main interest of the analysis was not the measured Scott Bond value, but the point of failure (i.e. where in the z direction the board broke). In more detail, 50 samples from the Reference trial and 25 samples from the Inventive trial were subjected to Scott Bond testing and then analyzed visually and weighed to determine the point of failure in the z direction. The results are presented in Fig. 2, which shows that for the samples from the Reference trial, 80% (40/50) of all failures occurred in the middle layer and only 20% (10/50) of the failures occurred in the middle layer/ print layer interface. In contrast, for the samples from the Inventive trial, 12% (3/25) of all failures occurred in the middle layer and 88% (22/25) of the failures occurred in the middle layer/print layer interface. It is believed that the main reason for this repositioning of the failures from the middle layer interior to the middle layer/ print layer interface was the change of CTMP quality. Further, it is known from earlier research that delamination in the interfaces rather than in the middle layer significantly reduces the cracking tendency during converting to LPB packages (Nygards et al., PAPER PHYSICS, Nordic Pulp & Paper Research Journal Vol 29 no (3) 2014).

Couching dryness trial

[0046] To test the influence of the web dryness at the couching stage, results from two full-scale machine runs were compared. In one of the runs, the dryness of each web was about 16% (the “high dryness run”) and in the other run, the dryness of the back layer and middle layer webs was still about 16%, whereas the dryness of the print layer web as about 7% (the “low dryness run”). Otherwise, the operating conditions of both machine runs were about the same as those of the Inventive trial described above.

[0047] The shear strength profiles across the z direction of boards produced in the high dryness run and the low dryness run were established according the methodology described in Nygards et al. (see full reference above). The results are presented in Fig. 3, which shows that the low dryness run resulted in a middle layer/print layer interface of significantly higher strength.