A new coating binder technology designed to provide high performance in both coated printed and packaging grades has been developed. It is based on novel Ultra-Fine Particle Size Technology (UFPST). The technology provides an environmentally responsible alternative to the current binder systems by allowing for a significant reduction in total binder levels, thereby lowering a mill’s carbon footprint and concerns around biochemical oxygen demand (BOD).
The ultrafine particle size allows for significant reductions in binder level without significant reduction in surface strength. Binder level replacement ratios of 2:1 are typical, however higher replacement ratios have been achieved, significantly reducing coating costs. Reducing the overall binder level leads to an increase in the system’s Pigment Volume Concentration (PVC). Increasing the PVC yields significant enhancements in coating bulk, fiber coverage, optical properties, and ink set rates. With the application of this technology, ink set rates have been increased without picking or piling.
The increase in PVC created with the UFPST produces a more open coating structure, which can be favorable for digital grade applications. This structure can significantly reduce the after coater drying demand, providing added energy savings.
Keywords: Binder types, coating technology, coating costs, novel composition, pigment volume concentration, ultrafine particles size technology.

* Authors*: Robert Hardy
Christopher M. Lewis

Authors’ reference:
1. Kemira Chemicals, Inc. - USA