PAPER SACK DEVELOPMENT AND INNOVATION

BillerudKorsnäs Smarter Packaging Seminar, Johannesburg, South Africa

2017-10-10 Mikael Peterson, Technical Service Director

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INNOVATION DRIVERS FOR PAPER SACK DEVELOPMENT

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PAPER SACK HEROES

James Arkell

Margaret Eloise Knight

Sanford Cluett
Adelmer Bates
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PAPER SACK HEROES

The Sack Solutions Crew

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THE PAPER SACK IS BORN

Cotton bags were used for flour and grain

During the american civil war 1861-65 cotton was difficult to obtain
James Arkell, Benjamin and Adam Smith made paper sacks made of manila
rope in Canajoharie, NY.
James Arkell received a patent for a paper sack machine in 1860’s

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MARGARET ELOISE KNIGHT

“The most famous 19th-century woman inventor".

Hired by the Columbia Paper Bag Company in
Springfield Massachusetts in 1867
Invented the flat-bottomed paper bag 1868
Charles Annan stole her design and applied for a
patent.
”Such a machine can never have been invented
by a woman”
Margaret won the legal battle and recieved her
patent in 1871

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SALT – INSPIRATION FOR INNOVATION

1890’s the demand for salt booms

They could not supply due to slow filling
Adelmer Bates was a salt salesman

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THE VALVE SACK IS INTRODUCED

1899 Adelmer Bates invented a self closing valve

for fabric bags
Mr Bates then continued to work on a valve sack
filling machine for increased productivity
1902 Adelmer Bates and John Cornell made a
valve for paper bags
1925 Bates Valve Sack Co opens and produces 40
million bags the first year

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THE ARROW COLLAR

Cluett & Peabody Co; Troy New York

Detachable collars
1920’s attachable collar shirts grew in
popularity
C&P Co started to make shirts
The shirts were shrinking…….

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SANFORD CLUETT

Sanforizing process - patent 1930

It is a method of stretching, shrinking and fixing a
woven cloth before cutting and producing,
Reduce the later shrinkage, which would
otherwise occur after wash

Paper was used when testing the machine

Paper became creased, but stronger!
Clupak process was born – new patent
Paper industry
Big paper machines 5-6 m width
Big investment

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THE PASTED STEPPED END VALVE BAG
INTRODUCED 1950

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PAPER DEVELOPMENT

Demand for sack paper grew

Lack of manila and cotton during WWII

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PAPER DEVELOPMENT

Demand for sack paper grew

Lack of manila and cotton during WWII

1950’s - New paper production technique

“Free” drying – web shrinking in CD
Pioneers: Fiskeby Skärblacka and Korsnäs

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PAPER DEVELOPMENT

Demand for sack paper grew

Lack of manila and cotton during WWII

1950’s - New paper production technique

“Free” drying – web shrinking in CD
Pioneers: Fiskeby Skärblacka and Korsnäs shrinking
zone
1950’s and 60’s – The Clupak unit paper
v2
Non rotating
pressed and
rubber stretched
blanket

Pressure
v1

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PAPER DEVELOPMENT

Demand for sack paper grew

Lack of manila and cotton during WWII

1950’s - New paper production technique

“Free” drying – web shrinking in CD
Pioneers: Fiskeby Skärblacka and Korsnäs

1950’s and 60’s – The Clupak unit

New modern machines and equipment
TEA has increased more than double over
the years

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WHAT BROUGHT INNOVATIONS?

Industrial revolution
Innovation of new machines
Curiousity and entrepeneurship
Lack of raw material
Productivity

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 WHY HISTORY?

The past caused the present

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WHAT ABOUT THE FUTURE?

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 Per Lindberg, CEO

The best way to predict the future is to create it!

 Per Lindberg, CEO

The best way to predict the future is to create it!

WHAT BRINGS INNOVATIONS TODAY?

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WHAT BRINGS INNOVATIONS TODAY?

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INNOVATION - TECHNOLOGY

Investment Skärblacka PM9 2015/16

QUALITY UPGRADE AND FOUNDATION FOR FUTURE

Improve the convertibility performance

Improve process stability
Investment enables further capacity and quality upgrades
Investment MSEK 260
New headbox
Upgraded HC refining

Confirmed significant quality improvment

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 INNOVATION – THE BAGGING TRIANGLE

Characteristics of filling goods

Sack performance Performance of

filling equipment
INNOVATION - TECHNOLOGY

Windmöller & Hölscher

Sack making machinery
Digital glueing technique

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INNOVATION - TECHNOLOGY
Haver & Böcker
Filling technology
Contributed to the moon landing!
Roto Packer
Ultra Sonic Sealing technology

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WHAT BRINGS INNOVATIONS TODAY?

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WHAT BRINGS INNOVATIONS TODAY?

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WHAT BRINGS INNOVATIONS TODAY?

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EXESSIVE EXPOSURE TO DUST CAN LEAD TO

Nose and throat irritation

Occupational asthma
Silicosis or scaring of lungs -
loss of lung function, severe
shortness of breath
High concentration can lead
to death
Regular Portland cement
10wt%<2µm
DUST EXPOSURE MEASURING
Handheld model
831 Aerosol Mass Monitor

Measures PM (Particle Matter);

PM10, PM4, PM2,5, PM1

PM10= The concentration of particles that is smaller

than 10 µm, measured in µg/m3
Extensive dust measurements in many countries
A level of 100 is unhealthy; 500 is hazardous

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 DUST MEASUREMENT IN INDONESIA
During filling

PM10 [µg/m3]

25000

20000

15000

10000

5000

0
QF Clean WPP

QuickFill Clean vs KPK 60% decrease

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 DUST MEASUREMENT IN VIETNAM
On the conveyor

PM10 [µg/m3]

30000

25000

20000

15000

10000

5000

QF Clean vs KPK 70% decrease

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 DUST MEASUREMENT IN CHINA
During unloading in storage

PM10 [µg/m3]

6000

5000

4000

3000

2000

1000

0
QF Clean WPP

QuickFill Clean vs WPP 75% decrease

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 DUST MEASUREMENT IN GERMANY

High porous paper sacks

PM10 : < 800 µg/m3

95% less dust compared

to filling KPK in SEA

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CEMENT DUST QUANTIFICATION

Cement loss after the drop test of

WPP sacks in India.

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CEMENT LOSSES
100 grams of cement

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CEMENT LOSS STUDIES
China India Vietnam

WPP WPP KPK

50 g/handling 50 g/handling 30 g/handling

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CEMENT LOSS COMPARISON

QuickFill® KPK WPP

Clean
Cement loss per 2g 30 g 50 g
handling
Number of handlings 7 7 7
(average)
Total losses per 50 kg 14 g 210 g 350 g
sack

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ADDITIONAL MATERIAL WASTE

Additional losses
During filling
First seconds on
conveyor
Up to 500 grams
BUT there is even more
Filling machine factors
Maintenance costs

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 VALUE OF DUST – EX. LOST CEMENT

Cement production (tpa) 1 000 000

Total cement lost per sack (kg) 0,36
Total cement lost per year (tons) 7 200
Lost turnover (USD) 430 000
Wasted annual carbon footprint (ton CO2) 6 674

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VALUE OF DUST – EX. LOST CEMENT
180 40-ton trucks lost…..

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 INNOVATION – COST AND PRODUCTIVITY

Problem: Cost (and breakage) Problem: Productivity

Solution: Higher strength Solution: Higher porosity
BILLERUDKORSNÄS QUICKFILL® SACK CONCEPT
Introduced 1998 – almost 50 years after the pasted stepped end sack

Very strong
2 ply, low grammage

High performance
High porosity
Fast and accurate filling

Cost efficient
Less material

Dust free
Environmental friendly
SMARTIFY YOUR PACKAGING

We have a well-defined three-step process to

improve packaging and explore new innovations

1 2 Needs
assessment and
verification
Lab analysis and
development 3 Smart solution
implementation
TECHNICAL SERVICES & TOOLS

SACK LABORATORY

Pilot filling machine

Automatic drop tester
Friction tester
Deaeration tests
Printing lab
Barrier lab
Paper testing facilities
WHAT BRINGS INNOVATIONS TODAY?
 BILLERUDKORSNÄS QUICKFILL® CLEAN
PAPER SACK TO REPLACE PLASTIC SACKS

To replace plastic sacks (KPK, WPP)

Designed to match benefits of plastic sacks
Very tough conditions
BILLERUDKORSNÄS QUICKFILL® CLEAN
PAPER SACK TO REPLACE PLASTIC SACKS
 BILLERUDKORSNÄS QUICKFILL® CLEAN
PAPER SACK TO REPLACE PLASTIC SACKS

To replace plastic sacks (KPK, WPP)

Designed to match benefits of plastic sacks
Very tough conditions
Extremely strong
2x120 gsm QuickFill paper
50% stronger than regular paper sacks

Keeping benefits of the QuickFill concept

High performance
Fast filling
Dustfree
Environmental friendly
 BILLERUDKORSNÄS QUICKFILL® CLEAN
NOW OFFICIALLY LAUNCHED IN VIETNAM
Vissai Cement Corporation, part of Vissai Group, officially launched the
QuickFill® Clean (QFC) eco-friendly cement paper bags on Monday 25 Sept at
the Vissai Ninh Bình cement plant.

“Vissai has studied and tested many types of cement sacks

produced in different countries for both the domestic and export
market. However, BillerudKorsnäs’ product is by far the most
competitive in terms of technology and cost”
Vissai’s deputy general director Nguyễn Tiến Đạt

BK Crew
ADDITIONAL PRODUCT PROTECTION

Required for retailers and consumers

Sacks sometimes stored outside and
exposed to weather and rain
Prolonged shelf life required
Additional water protection required
Previously plastic was the only option
ADDITIONAL PRODUCT PROTECTION

Required for retailers and consumers

Sacks sometimes stored outside and exposed to
weather and rain
Prolonged shelf life required
Additional water protection required
Previously plastic was the only option
Not any more – now there is RainSafe!
RAINSAFE – HIGH PERFORMANCE CONCEPT

Rain resistance
Resist min 4 hour hours of rain
Standard = DIN EN ISO 2875
8 hours with sealable valve
Shelf life
Customised
Sustainability
Sustainable nature of paper sacks
maintained
Filling performance
Certified by Haver and Boecker

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RAINSAFE – ADDED VALUE

Differentiation opportunity
Rain safety
Attractive appearance

Convenience
No need to cover sack on building site during
rain showers
Enabling occasional outside storage

Reduction in product/raw material losses

Minimise loss in filling, transport and handling

Real sustainability credentials

Recyclable, renewable

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WHAT BRINGS INNOVATIONS TODAY?

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PACKAGING IS IMPORTANT

Transport
Protect
Branding
Instructions
After life?
D-SACK - THE PACKAGING THAT DISAPPEARS

Protects the content when exposed to weather conditions and then dissolves
when put in a concrete mixer!

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BENEFITS OF D-SACK

PRODUCT ADDED VALUE

Comfort Ecological Health &Safety

Direct placement in mixer No waste

Lower dust
Fewer tasks Lower dust
Site safety
No bag cutting required No transport for disposal

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 BILLERUDKORSNÄS FOR SMARTER PACKAGING

Adds value to brands Increases productivity

Lowers transportation costs Reduces waste Lowers environmental impact

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