• Water resistance effectiveness
FEFCO N° 9 achieved with 20 % to 50 % less resin translates directly
into a chemical cost saving together with quality improvements and
reduced claims.
• Board quality and flatness for single wall and
microflute board
Because the bond strength is improved the glue application can be
reduced by 15 % to 20 % without risk of bond failure, giving a more
stable final board with less warp and washboarding which is particularly
important for micro and nano flute production. This leads to savings in
corrugator waste and converting downtime while improving productivity
and reducing adhesive consumption.
V
ECTOR® N-7070 has been used to replace maize starch for the
production of clay-coated B-flute as well as E-flute, improving board flatness.
Even difficult claycoated grades can be run at high speed with reduced levels of
adhesive and heat.
Speed increase
Adhesive
consumption
B flute 2450 mm
WT 175/R140 Clay coated kraftliner 180
+ 10 %
(180 to 200 m/min)
- 20 %
E flute 2450 mm
WTL140/R105 Clay coated kraftliner 130
+ 25 %
(140 to 175 m/min)
-10 %
E flute 2450 mm
TL140/R110 WTL140
+ 17 %
(190 to 222 m/min)
-10 %
Board Description
• Storage time reduction
Another source of savings lies in reducing intermediate production
storage to a minimum and maximising the efficiency of just-in-time
delivery. Industrial experience has shown that board produced with
VECTOR® N can be converted almost as soon as it comes off the
corrugator.
VECTOR
®
N adhesives provide new possibilities for corrugated
board makers especially in terms of productivity, water resistance and board
quality.
The ROQUETTE technical team is always available to assist in
obtaining the maximum benefit from the VECTOR® N range of products.
www.roquette.com
Authors : Christian BOUXIN – ROQUETTE Frères Lestrem - Martin GEORGESON – ROQUETTE UK Ltd - Industrial Starches business Unit
Contacts : [email protected] - [email protected]
ROQUETTE
introduces VECTOR® N
Range of SPECIALTY STARCHES
For the CORRUGATED BOARD INDUSTRY
S
ince the introduction of the Stein- Hall process and the replacement of silicate
by high-solids starch based adhesives, machine speed has dramatically increased thanks to
starch’s ability to bond quickly and safely different kinds of papers on any corrugator. These
adhesives have not yet reached their bonding limits on modern single facers.
H
owever there were still areas for further starch development in corrugating
including sectors such as micro-flute board, agricultural boxes, double-wall board, heavy-duty
board and water-resistant board.
R
OQUETTE is introducing a new technology and a new starch range to the
traditional range of products for the corrugating industry. This is to complement the wellknown capabilities of maize, wheat and potato starches.
1. Maize starch is the most versatile starch currently used and is able to bond
securely in many different conditions. It is considered limited in terms of speed
for double-wall production. However it resists heat and prevents brittle bonding
at low speeds and is the most widely used starch in the corrugating industry.
2. Wheat starch gives higher speed in double wall production compared to maize
starch but at the expense of brittle bonding at the low speeds experienced during
order changes.
3. Potato starch is currently the best performing starch for double wall and triple
wall production. It is used as secondary starch on middle and top tray of the
glue machine to improve production speeds of heavy duty board. Potato starch is
not suitable as a carrier starch and needs to be used in conjunction with maize
starch; also it cannot be used at the single facer.
Heavy duty commercial and agricultural board
Heavy duty board productivity is limited by the heat transfer rate to the upper
bonds on the double backer. The heat has to be transferred through the papers to the bond
under a low application pressure, heat transfer is therefore slow. In addition, such boards often
need to be water resistant and require increased application of conventional adhesive and
resin, which further reduces the production speed.
Micro and nano flute board
Micro and nano-flute boards are used as a marketing tool for the packaged
products and printability is high on the list of requirements. Priorities required include: board
flatness, absence of washboarding and no surface damage of coated liners. Such requirements
can only be met by running with minimum glue gaps and minimum steam pressure. Indeed the
optimum settings for high quality micro-flute board create a demand on the glue which is very
similar to heavy-duty board production.
New perspectives
VECTOR N Range, newly developed technology by ROQUETTE, responds to all
Industrial applications
VECTOR N Range has demonstrated its performance in terms of :
®
®
criteria needed for heavy duty and micro flute board production
• Productivity for double and triple wall production
Lightweight double-wall to heavy triple-wall production speeds can
be increased by 20 % to 100 %, with a corresponding increase in
productivity, as shown in the examples below :
• Good adhesive penetration
The amylose content of this product range
is higher than conventional starches such as
maize, wheat and potato but lower than high
amylose hybrids of maize. The particular
structure of the starch makes it possible to
totally solubilise the amylose portion: even
the amylose contained in secondary starch is
dissolved when the secondary starch swells and
participates in the penetration and anchoring of
the glue within the papers.
• Heat sensitivity
The graph alongside shows the energy
consumption of VECTOR® technology
compared to potato starch
• Rapid bond strength
development
The green bond development of the new
technology is quicker and reaches a higher
level than potato starch. This ensures faster
bonding and allows higher production
speeds. Combining the two graphs shows that
VECTOR® N achieves the same level of green
bond strength with less than half the energy
needed for potato starch.
• Water-resistant board
The high amylose content of the adhesive gives
an easier cross-linking reaction with resins and
FEFCO N° 9 test can be achieved with a 20 to
50 % reduction in wet strength additive.
• Pre-conversion storage
The bond strength development during curing
is shown in graph and shows why the new
technology virtually eliminates the need for
storage before conversion.
• Thin film forming capability
The visco-elastic behaviour of the adhesive
is such that the viscous adhesive becomes
elastic when sheared between the glue roll
and the doctor roll and transferred from glue
roll to paper. This provides a clean transfer of
adhesive without splashing and decreases the
starch deposit by 10 % without modifying the
glue gap settings.
VECTOR® N-7152 in comparison to potato starch
Potato starch
29,6 % solids
VECTOR® N-7152
28,6% solids
Double wall BC 2450 mm
B:KL300/ M110 C:TL180/ M127 KL 300
110
m/min
160
m/min
+ 45 %
Triple wall BKC 2450 mm
B:KL400/M150 K:KL300/ SC175
C:KL300 / M180KL400
75
m/min
120
m/min
+ 60%
Board Description
VECTOR® N-735 in comparison to high amylose
starch/maize starch
Board Description
Water resistant board
Speed increase
Adhesive
consumption
+ 33 %
(180 to 240 m/min)
- 20 %
VECTOR® N-735 in comparison to a speciality low
gel point maize starch
Speed increase
Adhesive
consumption
Triple wall ACA 2310 mm
A:KL400/SC180 C:KL 300/SC180
A:KL400/SC180KL300
+ 110 %
(50 to 105 m/min)
- 20 %
Triple wall ACA 2450 mm
A:KL400/SC180 C:KL 175/SC180
A:KL175/SC180KL300
+ 83 %
(60 to 110 m/min)
- 20 %
Board Description
These are just a few examples of an already proven technology used
by many corrugating mills for their double and triple wall productions.