Recyclability for paper and board from the viewpoint of de inking

Recyclability for paper and board from the viewpoint of de-inking

Dr. SHIMIZU, Hirokazu Visiting Senior Researcher, Waseda University Environmental Research Institute

President, SHIMIZU PRINTING INC. Expert, ISO TC130 WG11 (Environmental impact of printed products)

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Contents1. Background

A. Paper and board production B. Main paper recovery pathway C. Paper and board recovery rate and utilization rate

2. Experiment A. De-inking test procedure for UV ink in Japan B. Controversial points for test procedure C. De-inking test results from 4-different ink

3. Discussion A. Possibility of establishing a rule for recyclability

based on de-inking

2

1.BackgroundA. Paper and board production (worldwide, 2012)

3

00

0t

0

10,000

20,000

30,000

40,000

50,000

60,000

70,000

80,000

90,000

100,000

110,000

Chin

a

USA

Japan

Ger

man

y

Swed

en

Kore

a

Can

ada

Finla

nd

Bra

zil

Indones

ia

India

Ital

ia

Fran

ce

Russ

ia

Spai

n

Aust

lia

Mex

ico

Thai

land

UK

Tai

wan

11,417

22,63026,083

74,375

102,500

Reference: RISI Annual Review 2013

Annual production volume=399,985,000t

1.BackgroundA. Paper and board production (Japan, 2001-2012)

4

000t

10,000

12,000

14,000

16,000

18,000

20,000

22,000

24,000

26,000

28,000

30,000

32,000

Year2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012

12,332 12,158 12,061 12,103 12,051 12,042 12,074 11,80010,436 10,976 11,163 10,890

18,385 18,528 18,396 18,788 18,901 19,066 19,192 18,827

15,832 16,38715,446 15,067

30,717 30,686 30,457 30,892 30,952 31,108 31,26630,627

26,26827,363

26,60925,957

Total Paper Paperboard

Reference: Paper Recycling in Japan, Paper Recycling Promotion Center

1.BackgroundB. Main Paper Recovery Pathway

5Reference: Paper Recycling in Japan, Paper Recycling Promotion Center

Single/multi-family residences

Local shopping areas, office buildings, train stations..etc.

Shopping malls, paper packaging plants, printers, bookbinders, publishers, newspaper companies…etc.

Residential

Commercial

Industrial

Collection by local authorities

Group collections (Neighbors asso., PTA…etc.)

Drop offs (public facilities, supermarket…etc.)

Collectors

Sources

Scrap dealers

Intermediate agents

Reco

vere

d pa

per

supp

liers

Specialized collector

Pape

r m

ills

Expo

rts

Collection method

1.BackgroundC. Paper recovery rate (worldwide, 2012)

6 Reference: RISI Annual Review 2013

%

0

10

20

30

40

50

60

70

80

90

100

Kore

a

Japa

n

Ger

man

y

Cana

da

USA

Finl

and

Swed

en

Indo

nesi

a

Chin

a

Braz

il

44.444.652.5

61.062.264.473.2

77.678.0

94.6 Recovery rate=Collected paper

Domestic consumption

1.BackgroundC. Paper utilization rate (worldwide, 2012)

7 Reference: RISI Annual Review 2013

%

0

10

20

30

40

50

60

70

80

90

100

Kore

a

Chin

a

Ger

man

y

Japa

n

Indo

nesi

a

Braz

il

USA

Cana

da

Swed

en

Finl

and

5.314.2

24.5

35.443.3

57.464.3

71.672.9

84.5Utilization rate

Consumption of recycled paper

New pulp

=

Consumption of recycled pulp

+

+ Recycled paper

Recycled pulp

+ Raw materials

+

2.Experiment

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A. De-inking test procedure for UV ink in Japan

Reference: Paper Recycling in Japan, Paper Recycling Promotion Center

1-Pulping 2-Screening 3-Kneading

4-Floating5-Bleaching6-Cleaning

Paper recycling process at paper mills

2.Experiment

1. Printing sample Print UV Bk ink (density=1.60-1.80) on fine paper (64gsm, Oji Paper Mill) by tester, not by real press Cure the ink by either Hg or Fe lamp (120W/cm) at the speed of 30-40m/minute, temperature-aging at 60℃ for a week

2. Defibration (Pulping) 58g of paper (30mm×30mm…printed sheet=17.4g, white paper=40.6g) 1.5 litre of 28-32℃ water+6.9-7.1ml of 3.75% NaOH+6.9-7.1ml of 1.50% De-inking agent Agitate at 3000rpm for 20-minute Condense to 620-630g by using mesh configuration

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2.Experiment

3. Dilution Add 1350 ml of water and defiberize again for 1-minute Transfer tested pulp and add 28-32℃ water to make 5.4kg of 1.0% pulp density sample

4. Separating sample Separate 4.3kg of 1.0% pulp density sample and start floatation process

5. Floatation Put 4.3kg of 1.0% pulp density sample into JTAPPI No.39 and send air (3.8-4.2 litre/minute) to skim froth of pulp when rotating screw at1500rpm

6. Collection Collect pulp sample after stopping screws

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2.Experiment

7. 2nd dilution Add water again to increase pulp sample up to 8kg

8. pH adjustment Add aluminum sulfate for adjusting pH to be 5.0-5.6

9. Drying to make recycled paper sample Press and make 57-63g hand-sheet sample (5 or more) to from recycled paper sample

10.Measure Measure whiteness Measure dirt particle area (>0.05m㎡)

Measure number of dirt particle (>0.30m㎡)

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2.Experiment

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Printing samples

Ageing

Defibration

Storage

Floatation

J-Method for UV ink INGEDE Method11

*Bk density 1.60-1.80 *1-lamp of Hg/Fe at 120W/c㎡

Product categories: Newspapers, Magazines, Stationary/tickets/manuals

C=3.9%, t=20min., T=30℃, m=58g, speed=3000rpm

C=15.0%, t=20min., T=45℃, m=200g, speed=2

Oven: t=168h, T=60℃ Oven: t=72h, T=60℃

Water bath: C=5%, t=60min., T=45℃

1500g (m=58g)

625g (m=58g)

1975g (m=58g)

5400g (m=58g)

4300g (m=46g)

+1350g water

+3425g water

-900g water+pulp

Cell: C=0.8%, t=12min., T=45℃, m=180g,

Cell: C=1.1%, t=10min., T=30℃, m=46g, air=4l/min.

Reference: Assessment of Print Product Recyclability -Deinkability Test-, INGEDE

0.6% NaOH, 1.8% Sodium silicate, 0.7% H2O2, 0.8% Oleic acid

3.75% NaOH, 1.5% De-inking agent

2.Experiment

ISO related codes

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Reference: INGEDE Methods, INGEDE

Reference: Test method for recycle-focused UV ink, Japan Federation of Printing Industries

2.Experiment

Difference between J-Method (J) and INGEDE Method(I) Printing sample is categorized by products (I)

Methods for different materials (hot-stamp, sticker…) (J)

Testing fine paper only (J)

More evaluation parameters (I) • Luminosity

• Color

• Cleanliness

• Ink elimination

• Filtrate darkening

Definition in size for dirt particle area is much bigger (J)

Weighting is utilized for Rating deinkability scores (I)

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Quality of deinked pulp

Process parameters

2.Experiment

1. Tested not by real press? Recyclability test by real press is not considered

2. Printing speed of 30-40m/minute is appropriate? Actual UV energy is different from testing condition

3. Type of UV lamp can be Hg or Fe? Curing condition of ink can be totally different

4. Radiation distance by UV lamp should be defined? Distance from UV lamp to substrate is key factor for curing

5. Lifetime of UV lamp can be “averaged life-time”? Energy of UV lamp can be dropped suddenly at uncertain point

6. Ink density can be 1.40 or more on fine paper? When printing on coated paper at 2.00…1.25 on fine paper

7. Measuring device (filter setting) should be defined? Color density can be changed by different devices (different settings)

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B. Controversial points for test procedure

2.Experiment

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UV lamp house and reflector for manroland R710

2.Experiment

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UV lamp house is taken out from a press to check real lamp power directly by lighting UV lamp outside a press

2.Experiment

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Measuring UV lamps: pulling out a UV lamp house from a press, mount it on conveyor, and light a lamp. Then, check energy and power of a lamp by measuring device to know actual power on a press. Please do not try at your factory.

2.Experiment

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B. Controversial points for test procedureEnergy and power for different types of UV lamps

Item EyeGraphics EyeGraphics EyeGraphics EyeGraphics

Lamp Hg Hg Fe Fe

Usage h. 0h 900h 0h 900h

Type 160W/cm 160W/cm 160W/cm 160W/cm

Reflector Used Used Used Used

Position/speed 82mm, 25m/min. 82mm, 25m/min. 82mm, 25m/min. 82mm, 25m/min.

Energy/Peak

E(mJ/c㎡) P(mW/c㎡) E(mJ/c㎡) P(mW/c㎡) E(mJ/c㎡) P(mW/c㎡) E(mJ/c㎡) P(mW/c㎡)

1st 106 338 100 312 248 846 142 422

2nd 106 340 100 316 249 864 142 422

3rd 106 340 101 316 250 878 143 426

Avg 106 339 100 314 249 862 142 423

% 100% 100% 94% 93% 100% 100% 57% 49%

Usage hours for testing condition should be specified especially when using Fe lamp since its power could be half after using 900 hours

2.Experiment

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B. Controversial points for test procedureEnergy and power for different types of UV lamps

EyeGraphics EyeGraphics EyeGraphics

Lamp Hg Hg Hg

Usage h. 0h 900h 0h

Type 160W/cm 120W/cm 160W/cm

Reflector Used Used Used

Position/speed 82mm, 25m/min. 82mm, 25m/min. 82mm+20mm, 25m/min.

Energy/Peak

E(mJ/c㎡) P(mW/c㎡) E(mJ/c㎡) P(mW/c㎡) E(mJ/c㎡) P(mW/c㎡)

1st 106 338 79 260 93 280

2nd 106 340 78 258 94 280

3rd 106 340 78 258 94 278

Avg 106 339 78 258 93 279

% 100% 100% 74% 76% 88% 82%

Distance from UV lamp to substrate for testing condition should be clarified since curing power could be changed by position of UV lamp house

2.Experiment

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B. Controversial points for test procedureTotal energy by actual press (25m/min.)

160W: Fe(249)+Fe(249)+Hg(106)=604mJ/c㎡

160W: 604mJ/c㎡×(25m/min÷87m/min.)=173mJ/c㎡Total energy by actual press (87m/min.=7000s/h)

J std.: Hg=106mJ/c㎡×(25m/min÷30m/min.)=88mJ/c㎡J std.: Hg=106mJ/c㎡×(25m/min÷40m/min.)=66mJ/c㎡

Total energy by sampling test is much less than actual press

Printing sample for de-inking test is easier to be recycled than actual printed matters

2.Experiment

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B. Controversial points for test procedureColor densities (Bk) for 4-different ink

Device settingsUV-1

(Supersensitive)UV-1 (normal) Coventional Inkjet

Density standard: ISO-T

1.19 1.18 1.16 1.00White base: Abs.

Density standard: ISO-T

1.14 1.13 1.10 0.97White base: Paper

Density is 2.00 when printed on coated paper; it is impossible to be 1.60 or more on fine paper

Density value can be different when setting of measuring device is not the same; it should be clearly stated about measuring mode

2.Experiment

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C. De-inking test results from 4-different inkTesting conditions for 4-different ink

UV ink-1 (supersensitive)

UV ink-2 (normal) Conventional Ink jet

Ink density (ISO-T)

1.19 1.18 1.16 1.00

Paper OK Prince (fine paper by OJI)

OK Prince (fine paper by OJI)



Press manroland R707 manroland R707 Akiyama ?

UV device 120W, Hg 120W, Hg NA NA

Aging period1-week, normal

temperature1-week, normal



temperature

Unfortunately,type of inkjet cannot be specified

2.Experiment

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C. De-inking test results from 4-different inkWhiteness (ISO) for 4-different ink

ItemsNumber of

testsAvg Max Min SD

UV-1 (supersensitive) 10 72.85 72.95 72.75 0.0755

UV-2 (normal) 10 73.00 73.15 72.80 0.0101

Conventional 10 66.40 66.70 66.10 0.205

Inkjet 10 42.75 42.95 42.65 0.102

Inkjet show lower whiteness (lower than threshold?) because of small dirt specks entwining around fibre

2.Experiment

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C. De-inking test results from 4-different inkDirt particle areas (>0.05m㎡) for 4-different ink

ItemsNumber of

testsAvg Max Min SD

UV-1 (supersensitive) 5 196 223 165 22.1

UV-2 (normal) 5 290 338 260 30.1

Conventional 5 94.1 146 54.5 34.0

Inkjet 5 5.38 15.0 0.00 5.85

Dirt particles should be lower than 1300m㎡/㎡, so all of those can

pass criteria (because of low density of ink?)

2.Experiment

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C. De-inking test results from 4-different inkNumber of dirt particles (>0.3m㎡) for 4-different ink

ItemsNumber of

testsAvg Max Min SD

UV-1 (supersensitive) 5 0.00 0.00 0.00 0.00

UV-2 (normal) 5 0.20 1.00 0.00 0.45

Conventional 5 0.00 0.00 0.00 0.00

Inkjet 5 0.00 0.00 0.00 0.00

Number of dirt particles for UV-2 has ink spot; there was only one sheet which has a spot among 5-sample

2.Experiment

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C. De-inking test results by 4-different ink

Dried hand-sheet,UV-1 Dried hand-sheet,UV-2

Dried hand-sheet,Conv. Dried hand-sheet,Ink jet

2.Experiment

1. Whiteness (no criteria is specified) Ink jet is extremely low, so is considered as non-preferred one to be recycled though it can pass other criteria

2. Dirt particle area (total area of 0.05m㎡ should be less

than 1300m㎡/㎡)

UV-2 can pass the criteria though only UV-1 is regarded as “eco-conscious UV ink”

3. Number of dirt (a sample on which a dirt can be found should not be more than one among 5-sample) All inks can be considered as non-problematic inks

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C. De-inking test results by 4-different ink

3.Discussion

Testing and verification rules Printing: • Paper (type and thickness) • Energy (UV/LED) • Ink (density) De-inking: • Experimental processes • Experimental conditions • Standards for verification result Verification • Verification items • Scoring procedure • Criteria for determining

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A. Possibility of establishing a rule for de-inking

3.Discussion

Labeling rules Labels for recommended combinations of materials for printed matter Labels for reducing workload to separate paper for recycling at paper mills

Others Possibility to fix a rule to what extent? Who will study existing ISO rules relating to paper recycling test procedure and rules in different countries? Possibility to include surface coating and hot-stamping, sticker..etc.? Institutions working on recycling test should have approval and license? Any other rules for de-inking in other countries?

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A. Possibility of establishing a rule for de-inking

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Thank you for your close attention !

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Recyclability for paper and board from the viewpoint of de inking