|2012 August JAPAN TAPPI JOURNAL|
Vol.66, No.8 Abstracts
Trends of the Printing Market and gSMATRIX2020h, a Vision for the Printing Industry
Japan Federation of Printing Industries, Incorporated Association
The printing industry is facing unprecedented change in its operating environment. According to industrial statistics, the value of printing industry shipments has decreased from 8.3 trillion yen in 1990 to 8.1 trillion yen in 2000, 7 trillion yen in 2005, and then 6.9 trillion yen in 2008. The estimate for 2010 is that shipments were 6.4 trillion yen and the industry is fighting to maintain a level over 6 trillion yen. In particular, there was a significant year-on-year decrease of 8.4% in fiscal 2009. In addition to manufacturing, the printing industry should have the power to integrate and produce information through services, consulting, analysis, planning and development in order to overcome the adversity. This means that pushing forward with the creation of a foundation (MATRIX) for a new printing industry that can respond to a smart society is currently the most pressing issue. In other words, this is the construction of a SMATRIX. Based on this, it is necessary to consider the key issues for the evolution of the printing industry.
Trends in Coated Paper
Takehiro Yoshimatsu, Masanori Kawashima and Fuminari Nonomura
NPi Resarch Laboratory, Nippon Paper Industries CO.,LTD.
World annual production of paper and paperboard is estimated 390 million ton, and coated paper accounts for 20%, 80 million ton per year in 2008. Especially in Japan, the annual production of coated paper is estimated for 5 million ton, but imported coated paper from overseas is making an impact on the Japanese market year by year. The major exporting area of coated paper to Japan is Asia (58%) and Europe (34%). >From the view of coated paper grade, bitoko (LWC) occupied 58% of all imported and they were mainly from Europe (Sweden and Finland). A2 grade (WFC) showed the rest of 42% and mainly imported from China.
In this report, more than 10 samples are analyzed in paper sheet quality, printing quality and componential research. As a result, bitoko grade (LWC) shows high opacity, low brightness and almost the same print qualities compare to the domestic products. Meanwhile in A2 grade (WFC), the paper sheet quality of imported samples is the same as of domestic. It is characteristics that imported A2 grade shows heavy coat weights. Regarding domestic A2 grade in Japan, it is supposed that the overall trend will be weight saving and cost cutting for manufacturer. Japanese manufacturers recognize that it is necessary for competing in global market, to improve the matching performance between the world market and the suitable paper quality and to improve low cost manufacturing technology.
Extended Applications of Advanced Coating Technologies - ValSizer and OptiLayer -
Metso Paper Japan Co., Ltd.
The author introduces two different coating technologies which are attracting special concerns of paper- and board-makers for different purposes respectively. One is ValSizer, and another is OptiLayer simultaneous multilayer curtain coater.
ValSizer is a rod-metering sizer, which achieves uniform film transfer to web and has a large operating window for starch and coating color applications. Production of linerboard and corrugating medium grades from recycled fiber often struggle with challenges to reach required strength properties due to increased fiber recycling rate. Starch can be used on the sizer to compensate for the lost raw material strength.
OptiLayer multilayer curtain coater is a low-impact premetered coating method for coated paper and paperboard, which achieves contour coating with good fiber coverage. The coater adds several different coating layers to the web at the same time in a non-contact operation with essentially no speed restrictions. This gives extremely high efficiency with respect to coating chemicals, machine runnability, drying efficiency and overall cost of the process.
Polyurethane Cover for Applicator Roll - High Top Roll -
One of our products, High Top Roll, which is Polyurethane roll cover, has been used for Press Rolls and Applicator Rolls since it was first developed in 1963.We also developed High Top S series, which is the cover only for Applicator Rolls, in 1998 and we are keeping the top market share for domestic market thanks to its excellent performance.
Recently, the requirements for Applicator Roll Covers are becoming more critical due to the diversification of the chemicals, high temperature or high density of coating liquid especially for Rod Metering Size Press.
Yamauchi, as the leading company of roll covers, introduces the latest roll covers for Applicator Rolls, High Top SD series, which will take the place of the previous covers.
Operating Experience of PM N6 with On-Machine Coating
Ishinomaki mill, Nippon Paper Industries Co., LTD.
Commencing commercial production on November 2007, Ishinomaki PM N6 has mainly produced LWC and MWC. Having a width of 9,450mm wet fabric and an operating speed of 1,600m/min, PM N6 has also equipped with both blade coaters and hot soft nip calendars as the on-line units. PM N6 now reaches its maximum speed of 1,600m/min, and we tried various techniques to obtain more stable operation of the on-machine coaters.
This report summarizes PM N6's latest equipment, and recent operating experiences in the rod metering size press and on-machine blade coater of PM N6.
Latest Technology Trend in Electrophotographic Copier, Printer and Its Quality Demand for the Paper
OIP Device Technology Development Center, Canon Inc.
(Office Imaging Products Operation)
The copier of the photo-electrographic system has evolved corresponding with duties change by the immediate nature of image forming system that seeped from the copy making duties of documents in the office. Now the full color MFP (Multi Function Printer) becomes the necessary office business machine around a core of the various duties of the office. The below is the explanation for the office duties in conjunction with function of MFP.
MFP possesses the almost following functions. It has a function to copy, a function to print via network, a function to send FAX, function to store the scanned data to a folder on the network, a function to send by e-mail attachment.
Furthermore, the electrographic image forming system builds the position with an IJ printer as a digital printer in POD (Print On Demand) from the immediate nature. In this area, the characteristic technology are the print quality which is the equal of printing system and the paper feed technology to be able to use the same paper which is using for printing system.
Analysis of Defferent Premetering Techniques by Surface Sizing
- TWINTM Sizer, HSM and TWINTM Sizer, Gravure Developed by UMV Coating Systems AB -
Per Emilsson, UMV Coating Systems AB
UMV was founded in 1876 and became sister company with former BTG Coating Systems in 2002. The two companies were combined and got the name UMV Coating Systems in 2007. UMV Coating Systems is a supplier of coating machines since 1973 and the initial product was the Billblade coater, one of the most sold coaters in the world.
Cover Coat Materials for Coater Section
MEIJI RUBBER & CHEMICAL CO., LTD.
Meiji has a lot of rubber cover materials for the paper manufacture roll, and we are supplying the cover material that is appropriate for each section.
We developed "PRES COAT" first as a cover material for Coater Backing roll that was the preparation the maintenance done by the customer.
Afterwards, we developed "MULTICHEM" that improved abrasion resistance, and these two kinds of cover materials are popular, and used by a lot of customers.
In addition, we develop the product corresponding to customer's needs, and developed two kinds of cover materials of an "EXCEL COAT" and "SUPER COAT" in recent years.
Especially, "SUPER COAT" has an excellent feature in abrasion resistance and the dirt-proof character.
Moreover, we developed "Justie Coat" as the newest cover material.
"Justie Coat" has the excellent character for dirt not to be attached easily and to be easy to remove dirt.
In this time, we introduce the background of the development of cover material for Coater Backing roll. And we introduce the feature and the material physical properties etc. of each cover material.
Moreover, it introduces the usage condition in the customer and the evaluation by the customer.
Operating Experience of PM N10
Mishima MillCDaio Paper Corporation
The domestic market for coated paper is shifting to lighter products. In addition, the share of imported papers reached up to 22% in the domestic coated paper market. In this situation, we try to steadily supply users with our products which excel in both quality and cost competitiveness. This is why we constantly aim for stabilization in productivity while improving operation and equipment of our on or off-machine coaters.
The PM N10 that started commercial operation in September, 2007 is a high speed on machine coater which is adjusted to making lighter weight coated papers with a high percentage of recycled pulp. The machine has a roll coater and blade coaters in the coating section. In case of LWC grades, in which more importance is placed on high bulkiness and stiffness, the roll coater is used. In case of A3 grades, in which printing quality such as high gloss, reproductivity and so on are more important, we choose blade coaters which can create thicker and smoother film.
At present, we are challenging ourselves to make full use of the machine capacity to supply high quality products to more customers. In this report, we introduce several cases of operating improvements at the coating section experienced in the approach of increased speed.
Operation Experience of Blade Coater
Edogawa Mill ,Oji Paperboard Co. ,Ltd.
Oji paperboard Edogawa Mill is the only paper manufacturing mill in Tokyo. Edogawa Mill is located east of old Edogawa River and surrounded by residential quarter. In this mill, we produce white lined boards, taking advantage of collecting waste papers easily and the good location which is near consumption areas.
The #5 paper machine was constructed in May, 1971, as the first white lined board machine in Japan, with gHigh Speed Ultra Formerh of Kobayashi Engineering Works., Ltd. The machine produces about 140,000 tons of white lined board a year today. The products are mainly used as paper containers. Up to today, we have advanced the quality improvement according to progress of printing technology and converting technology. In August, 2006, we changed the top coating method from gAir Knife Coaterh to gBlade Coaterh for the purpose of a further quality improvement.
In this report, we report the summary of the remodeling, the operating experience, and the effects of the introduction.
Paper Gloss Analysis by Specular Reflection Point Spread Function(Part I)
-Measurement Method for PSF of Paper on Specular Reflection Phenomenon-
Shinichi Inoue, Yukio Kotori and Masayuki Takishiro
Process Development Laboratory, Mitsubishi Paper Mills Limited
Glossiness is one of the major qualities of coated paper. For example, coated paper is categorized to glossy or matt. Glossiness can be most usually measured using a glossmeter. The standard units for measurement are "specular glossh.
However it is well known that the gspecular glossh values, in some cases, do not correspond to the glossiness by the visual inspection. In this paper, a new technique for measuring the specular reflection light of paper is proposed. We have developed the apparatus to measure the Point Spread Function (PSF) of specular reflection. A pinhole test pattern is projected to the sample paper, and the reflection light intensity distribution is measured by the two-dimensional CCD camera. The specular reflection PSFs of different type of paper were obtained.
Results showed that the specular reflection PSFs of paper meet well with the visual inspection glossiness. We discuss the physical meaning of the specular reflection PSF. The specular reflection PSF works as transfer function for specular reflection image, naturally. In future work, we will discuss paper gloss evaluation by using spatial frequency analysis.