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A new potential paper resource; Recyclability of paper cups coated with water-
soluble polyacrylate-based polymer
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3 authors:
Jeong-Yong Ryu
Kangwon National University
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KEYWORDS: paper cups, polyacrylate, paper substrate with synthetic films to compensate
recyclability, flake, kneading, beating the defects of paper. Such synthetic films as a water
SUMMARY: Paper cups are typically made by barrier have several advantages. They can be easily
laminating PE or PLA onto the surface of paper. PE handled and formed with heat. In addition, water or
and PLA are hydrophobic and easy for film formation. beverages cannot directly contact the paper surface
However, recycling of PE- or PLA-coated paper cups due to the synthetic resin laminating layer. Various
is difficult. Polyacrylate (PA)-based polymers may be barrier materials have been investigated by many
an alternative to PE and PLA, and recycling of researchers. Among these barrier materials,
polyacrylate-coated paper cups may be considered polyethylene (PE) and polylactic acid (PLA) were
if the barrier film can be disintegrated. The chosen in this study. PE is the most common plastic;
recyclability of paper cups coated with PE-, PLA-, it has low strength, hardness, and rigidity, and is very
and PA-based polymers was investigated by pilot hydrophobic and non-biodegradable. Owing to these
pulper and screen. Furthermore, mechanical properties, PE has been used in the manufacture of
treatments were investigated for the removal of packaging materials in various fields including those
remaining polyacrylate flakes (RPF). The pulping of food packaging (Palma, et al., 2015; Hannon, et
yield of PA-coated paper cups was higher than that al., 2015), antioxidant coatings (Mahiyan et al. 2015),
of PE- or PLA-coated paper cups, since PE or PLA anti-bacterial coatings (Xu et al. 2015), and other
films were discarded as hole screen rejects. In the barriers (Ge, et al., 2015; Nakaya, et al., 2015) PLA,
case of PA-coated paper cups, RPF could not be on the other hand, is biodegradable, versatile, and
separated by slot screening due to its deformability. hydrophobic. According to previous research, PLA
However, RPF must be treated properly since it can could be coated onto the surface of white duplex
result in specks on the surface of paper. RPF could board by simple heating to give it water resistance
be fragmented effectively, with over 95 % (ECOIN Inc., 2009). Cheng et al. (2015), on the other
disappearing after one pass of kneading and 10 min hand, focused on the coating performance of PLA.
of beating. Consequently, it may be possible to use In their study, they improved the properties of PLA
PA-coated paper cups as a raw material in the paper as a paper coating material by the addition of
recycling process. modified gelatin. A new PLA-based hybrid coating
ADDRESSES OF THE AUTHORS: Tai Ju Lee was also studied as a barrier material, which was
(assorrow@kangwon.ac.kr): Senior researcher transparent and showed good barrier properties
Changgang Institute of Paper Science and against oxygen and water. However, paper cups
Technology, 1, Kangwondaehak-gil, Chuncheon-si, laminated by synthetic resins are very difficult to be
Gangwon-do, Republic of Korea, Cheol Yoon recycled with other recovered papers, since the
(cheolyoon@repaper.kr): Director, RePaper Inc., 1, laminating layer does not disintegrate by water and
Dongtanjungsimsangga-gil, Hwaseong-si, shearing forces in the paper recycling process.
Gyeonggi-do, Republic of Korea, Jeong Yong Ryu Moreover, with the increase in consumption of
(jyryu@kangwon.ac.kr): Professor, Dept. of Paper instant food and beverages, the demand of paper
Science & Engineering and 1, Kangwondaehak-gil, cups is increasing. In the light of the above, and
Chuncheon-si, Gangwon-do, Republic of Korea since the fibers in paper cups are valuable to use as
Corresponding author: Jeong Yong Ryu a raw material in papermaking, it is therefore
Paper, made of cellulose that is formed by 1-4 necessary to investigate recycling technologies of
linkage between glucoses, is typically very sensitive paper cups.
to water. Glucose has three free hydroxyl groups Recently, water-based coating agents as a water
that are attached to the number 2, 3, and 6 carbons. barrier was invented by Ahn, et al. (2003) They
Water can easily penetrate into a paper structure laminated the inner surface of paper cups with a
through pores, after which breaking of hydrogen hydrophilic coating agent that could possibly be
bonding can occur. A hydrophilic character and applied to food packaging. Those paper cups could
porous structure as a water barrier is therefore then be easily recycled compared to PE-laminated
inappropriate for paper cups. Therefore, paper cups paper cups. In addition, Yoon, et al. (2015) invented
are typically produced by laminating the surface of a an eco-friendly coating material for paper cups.
Silicone- and acrylate-based coating materials (b)
provided paper cups with good water and oil Fig 1 Monomer of PA-based polymer cited from
resistance, as well as biodegradability, and it was Yoon et al. (2015). (Rn = alkyl or arly group)
demonstrated that the paper cups coated with these Apparatus
materials could be easily recycled. Pilot pulper
Slushing or pulping can separate pulp into individual A pilot pulper as shown in Fig 2 was used for the
fibers and make a pumpable slurry. This stage is the slushing process of paper cups. This pulper was a
primary unit in the papermaking process and occurs low consistency pulper. The vat of the pulper was
in a pulper. In brief, pulp or recovered paper and comprised of cylindrical stainless steel. Slushing
processing water are introduced into a pulper; occurred by rotation of the rotor at the bottom of the
hydrogen bonding between the fibrous raw materials pulper. The inside of the pulper was equipped with
can then be broken by wetting, and shear forces baffles. After slushing, a slurry could be obtained
generated by a rotor promote the defibration. When through the gateway valve. The total volume of the
slushing is finished, a pumpable slurry is fed to a pilot pulper was 20 L (Amend, et al., 1997).
high-density cleaner and screening stages through
a perforated plate at the bottom of the pulper.
Therefore, the screening and cleaning efficiency will
be dependent on the initial stage. If slushing is poor,
the process runnability and the properties of the final
products will also be poor.
As mentioned above, a PA-based coating could be
a new method to produce eco-friendly paper cups in
terms of improved recyclability. In order to confirm
Fig 2 - Pilot pulper cited from Lee et al. (2015)
whether poly acrylate-based coating materials would
be a good alternative to PE or PLA, the recyclability
of the newly-developed paper cups must be verified.
Pilot screen
The purpose of screening is to remove debris and
In this study, the recyclability of paper cups using
flakes present in the slurry after slushing. This
different coating materials (PE, PLA, PA) was
screening process is an essential stage to evaluate
therefore evaluated by comparing the efficiency of
the recyclability of paper cups. As shown in Fig 3, a
slushing, screening, and flotation. Furthermore,
pilot screen was used for separation of the
mechanical treatments to improve the recyclability of
components in the slurry. This pilot screen has holes
PA-coated paper cups were also investigated.
with a diameter of 3 mm and slots with a width of 0.3
mm. Therefore, the screen can be separated
Materials and Methods sequentially according to particle size. Slurry could
Materials be pumped into the screen basket through the 3 mm
Three types of paper cups were investigated. Paper holes at the bottom of the screen. When particles are
cups were obtained from rePAPER Inc. (Gyeonggi- larger than these holes, that fraction was separated
do, Republic of Korea). PE, PLA, and PA-based as hole rejects. The slurry that passed through the
coating materials were coated onto the surface of holes was then separated by the slots. Fibers would
the same base paper with grammage of 300 g/m2. pass through the slots due to centripetal forces
Chemical structure of PA-based polymer can be generated by the rotatory power of the foils.
described in Fig 1. As shown in Fig 1, the monomer Simultaneously, flakes or debris with a size larger
of the polymer are silicone and polyacrylate. than the slot width was discarded as slot rejects.
Finally, three kinds of fraction were obtained from
the pilot screen.
.
(a)
20
about 8%. According to these results, small or soft
15
flakes of PA-coated paper cups could pass through
10
the slots in the pilot screen. We consider that these
flakes had an effect on the decrease in fiber content.
5 Accordingly, a decrease in strength and optical
properties of the paper can be caused by the flakes
0
PE PLA PA
since they may be separated into the accept fraction
by the centripetal forces in the screen. The fiber
properties after flotation are shown in Table 1. The
Fig 6 - Hole, slot and flotation reject fractions from fiber length and width of PA-coated paper cups were
the three kinds of paper cups. (PE: polyethylene; lower than those of PE- and PLA-laminated cups.
PLA: polylactic acid; PA: polyacrylate) However, the fibril perimeter and freeness were
similar.
140
Flake
Ratio of flake, fiber and fines, %
120 Fiber
Fines
100
80
60
20
0
PE PLA PA
PA-coated 50
0.7 19.6 8.8 636
paper cups
paper cups were poor since their fibers had a shorter Fig 13 - Burst strength of sheets based on flotation
length than other fibers, as shown in Table 1. accept fractions.
Additionally, the residual flakes of PA-coated paper
cups can be considered a bad influence on paper
50
Light scattering coefficient, m2/kg
3.0
44 PLA
2.5
PE
PA
2.0
Bulk, cm3/g
42
78 80 82 84 86
1.5
Opacity, %
1.0 Fig 14 - Opacity vs. light scattering coefficients of
0.5 sheets based on flotation accept fractions.
0.0
PE PLA PA Effects of mechanical treatments on
Fig 10 - Bulk of sheets based on flotation accept. control of RPF
Fig 15 shows the ratios of flakes, fibers, and fines of
PA-coated paper cups corresponding to various
40
pulping time. Flake contents decreased with an
increase in pulping time, while fiber contents
30
increased. The content of fines however remained
Tensile index, Nm/g
Fig 11 - Tensile strength of sheets based on RPF decreased with an increase in pulping time
flotation accept fractions. because the flake content depends on the pulping
energy. However, pulping could not break RPF
completely, while excessive pulping energy
consumption can be caused by the increase in confirmed as suitable methods to control RPF.
pulping time. Accordingly, an increase in pulping Eventually, the amount of RPF is related to specks
time over 10 min is not efficient. Therefore, other in the paper. If RPF remains as a residue during
mechanical treatments were investigated for stock preparation, the appearance of paper will be
improved control of RPF. Fig 16 shows the results of poor. However, RPF can be well-controlled, since
flake, fiber and fines contents of kneaded stock. The paper recycling mills have mostly kneaders and
consistency was 18%, while 97.5% of RPF was beaters (refiners). Consequently, RPF can be
removed by kneading, even in just one pass. broken down by the beating and kneading actions
Generally, kneading is used in the paper recycling during the papermaking process.
process. Kneading can fragment dirt specks below
the visibility limit and break down large particles. In 140
120 Fiber
fines content.
Flake, fiber, and fines contents after beating are
80
Fibers can be bruised between the rotor and stator Fig 16 - Ratios of flakes, fibers, and fines after
by mechanical actions. At this time, fiber shortening kneading.
and internal or external fibrillation can be caused, 700
while RPF can be fragmented.
Fig 19 shows that freeness decreased with an 650
600
and fibrillation can be generated by beating. This
can be confirmed with the results in Table 3, showing 550
80 min mm µm
60 5 0.89 19.1 87.9 5.4
40
10 0.88 19.2 89.4 6.0
20 0.87 19.6 89.8 8.6
20
0
0 5 10 15 20 25 30
30 0.82 20.2 89.6 13.5
Beating time, min