DESC:FILM FACE SHUTTERING KRAFT PAPER MADE FROM RECYCLED PAPER FIBRE

FIELD OF THE INVENTION
The present invention, in general, relates to a film face shuttering kraft paper, and in particular, relates to a shuttering kraft paper made from recycled fibre extracted from steel mill kraft paper. The film face shuttering kraft paper of the present invention has improved strength properties.
BACKGROUND OF THE INVENTION
Background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
Kraft paper is a broad term in the paper industry as Kraft paper is generally referred to as the paper that is used for cardboard or cartons etc. Kraft paper is usually for brown color paper in the paper industry where the paper GSM is more than 120 GSM to 300 GSM paperboard or cardboard resulting from chemical pulp that is produced in the kraft process. Normally these papers are used for carton packing, shopping, handbag product wrapping, and other applications.
Various types of Kraft paper are made using recycled fibre. The available kraft paper uses virgin fiber or paper pulp as the raw material. However, the use of such raw material, for example, virgin fiber, is not sustainably viable since the virgin fiber or paper pulp is being obtained from trees and thus, leads to depletion of the environment.
Therefore, the present invention provides film face shuttering kraft paper made from recycled fibre extracted from steel mill kraft paper.
OBJECTIVES OF THE INVENTION
An aspect of the present invention is directed towards film face shuttering kraft paper made from recycled fibre extracted from steel mill kraft paper.
Another aspect of the present invention is directed towards a film face shuttering kraft paper having high strength properties.
Another aspect of the present invention is directed towards a film face shuttering paper made from recycled paper fibre to produce the colour kraft paper and film face paper.
Another aspect of the present invention is directed towards a film face shuttering kraft paper made from recycled paper fibre extracted from steel mill kraft (dry or oil) and New Double Lined Kraft Cuttings (NDLKC) or double-sorted corrugated containers OCC, along with chemical mixtures.
While the invention has been described and shown with particular reference to the preferred embodiment, it will be apparent that variations might be possible that would fall within the scope of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The following description includes the preferred best mode of one embodiment of the present invention. It will be clear from this description of the invention that the invention is not limited to these illustrated embodiments but that the invention also includes a variety of modifications and embodiments thereto. Therefore, the present description should be seen as illustrative and not limiting. While the invention is susceptible to various modifications and alternative constructions, it should be understood, that there is no intention to limit the invention to the specific form disclosed, but, on the contrary, the invention is to cover all modifications, alternative constructions, and equivalents falling within the scope of the invention as defined in the claims.
In any embodiment described herein, the open-ended terms "comprising," "comprises,” and the like (which are synonymous with "including," "having” and "characterized by") may be replaced by the respective partially closed phrases "consisting essentially of," consists essentially of," and the like or the respective closed phrases "consisting of," "consists of, the like.
As used herein, the singular forms “a”, “an” and “the” designate both the singular and the plural, unless expressly stated to designate the singular only.
The term “one embodiment” means that a particular feature, structure or characteristic with the product/system described in connection with the embodiment is included in at least one embodiment of the present invention.
One embodiment of the present invention is directed towards a composition of film face shuttering kraft paper includes a recycled fibre extracted from steel mill kraft paper, and a recycled fibre extracted from paper selected from New Double Lined Kraft Cuttings (NDLKC) and double-sorted corrugated containers OCC.
In another embodiment of the present invention, film face shuttering kraft paper made from recycled fibre extracted from steel mill kraft paper and/or New Double Lined Kraft Cuttings (NDLKC), and/or Old cartons waste paper, along with chemical mixtures.
In a preferred example, film face shuttering kraft paper made from the recycled fibre extracted from steel mill kraft is in the range of 1-100% and the recycled fibre extracted from paper selected from New Double Lined Kraft Cuttings (NDLKC) and double-sorted corrugated containers OCC is in the range of 1-60%.
This film face shuttering kraft paper of the present invention has high strength properties.
In another preferred example film face shuttering kraft paper made from recycled fibre extracted from 99 % steel mill kraft paper and 1% other paper selected from New Double Lined Kraft Cuttings (NDLKC), and Old cartons waste paper.
In another preferred example film face shuttering kraft paper made from recycled fibre extracted from 60-99 % steel mill kraft paper and 1-40 % other paper.
Other papers are selected from the New Double Lined Kraft Cuttings (NDLKC), or Old cartons waste paper.
The recycled paper fiber is further incorporated with chemical mixtures such as red oxide/iron oxide/ferrous oxide along with wet strength resin, and/or pigments, and/or resin.
In an example, film face shuttering kraft paper made from recycled paper fibre is converted to the colour kraft paper and film face paper.
The paper of the present invention has GSM of 40/42 gms per sq meter, breaking length at the machine direction side is more than 6000 meters minimum, and at the CD side (cross direction) is more than 2000 meters minimum. The thickness range of paper is between 50-60 grams per square meter. The wet strength of paper is above 500 grams in the paper. The Water Klemn in mm/4 min test method is between 8-12 in the paper. The degree SR at refining the final pulp at machine chest is maintained between 28-37 for the paper properties to be achieved. The paper Ash % due to addition of Red Oxide is above 8% in the paper.
Comparison Test Report between the color kraft paper of the present invention and color kraft paper made of virgin fibre available in market

SL Description Unit Std. Specification Color kraft paper of the present invention Available color kraft paper made of virgin fibre
1 Standard Gsm GM/M2 40 40 40
2 Avg. Gsm GM/M2 ±1.0 40.1 41.2
3 Thickness µ 54-56 55 60
4 Bulk cm3/gm 1.35-1.40 1.37 1.45
5 Burst Strength 0.80 0.9 1
6 Burst Factor _ 20+ 22.4 24.2
7 Tearing Strength M.D 22 22 24
C.D 26 26 28
8 Tear Factor M.D _ 55.0 54.86 58.2
C.D _ 65.0 64.84 67.9
9 Wet Strength Gms 260-300 750-800 580-600
10 Tensile Strength M.D Kg./15mm 3.60 3.96 4
C.D 2.10 1.7 2.5
11 Breaking Length M.D Meter 6000 6584 5872
C.D 3500 2826 3845
12 Smoothness (Gurley) Sec/50ml 18-20 25 23
13 Porosity (Gurley) Sec/100ml 25-30 (Max) 16-18 18-20
14 Ash Content % 9 .0-10.0 10.0 11.0
15 C.O.P at 35°C (Top) Sec./35°C 10.0 11 8
16 Water Klemn mm/4 min 8.0-10.0 10 13
17 Paper Formation _ Good Normal Good
18 Moisture % 3.5±0.5 2.9 3.5
19 Shade Sample _ Reddish Deep Redish Reddish

Method of Preparing the paper of the present invention
Preliminary step:
Extracting the recycled fibre from the steel mill kraft paper and/or other papers.
It further includes the known steps of the method as follows:
Step 1: feeding raw material into a pulper through a conveyor:
CONVEYOR
The conveyor is being used to feed raw materials into pulper. It is being operated by electric and following all safety norms. It avoids manual feeding and reduces manpower. With a load cell provision, the exact quantity is being added into pulper. It has a large loading capacity. It is mainly used for conveying various kinds of bulk or bundled materials and to be feed into pulper. With robust structure, adopt chain plate transmission, drive and conveying material trough plate movement, has the large conveying capacity, low power consumption, less wear and tear, reliable work. Strive to even feed material when it is in operation, feeding maximum weight should be controlled in the specified scope, stop or start when Stop or start is not suitable, in the operation it should be frequently checked and adjusted.
HIGH CONSISTENCY PULPER
High consistency pulper is being used for batch process at a controlled raw material, chemicals and water addition for a certain fix time circulation to get better and uniform quality. It is designed with a principle of the hydraulic whirlpool. Rotors are designed in such a way to get better hydration and to accelerate defibering. The specially designed impeller of the rotor are oblique spirochete, the shear effect is weak, only divestitures the impurity in the raw material, and it will not form of small flakes, so it creates favorable conditions for pulp screening. It runs between 13%- 16% high consistency pulp, effective chemical mixture and friction between fibers under high consistency make the sticky particle separate from the surface of fiber fully.
In another embodiment, different types of pulper such as hydra pulper or continuous pulper can be used based on the manufacturing unit of the paper.
Step 2: Screening of the pulp produced by the pulper:
SCREENING
Screening is a key process in pulp and paper production and is used to enhance the quality of pulp destined for a wide range of pulp and paper products. For such any type of equipment that has screen can be used like coarse screen or Turbo.
While the usual goal of screening is to remove oversize contaminants from the pulp, it is finding increasing use for fiber fractionation as well. Product quality can be improved by fractionating fibers for targeted processing or for use in specialty paper products. For any paper mill screen, selection is a significant matter. All type of screen is not suitable for all kinds of fiber. To select a screen it should be considered the kind of fiber, filler, cost and repair, power consumption, efficiency, capacity, space required, etc.
Various factor effect on screening performance. Various factor that effects on screening performance such as stock consistency, type of fiber, type and size of holes, type of plate cleaning mechanism, level of coarse fiber and foreign matter, rejection rate, flow configuration, flow rate, stock temperature, stock pressure etc. Water (consistency) has an important function in screening section, water acts as a conveyer for the fiber. The consistency of the pulp of the storage tanks may be 3 to 4 percent. When the pulp leaving the storage tank, the consistency should be reduced by adding white water. The nature of pulp, the inlet consistency of the screening equipment should be 1.5% to 2.0% for optimum result. When the consistency comes over 2.0%, then the rejections will increase. The proper consistency of the stock ought to be 1.0% to 2.0% depending, on the type of pulp screening.
The diameter of the pulp screening equipment holes is another important variable for screening performance. In case of the coarse screen, it should not be more than 3/16 ins in diameter; but it is better to keep 1/8 ins in diameter. Whereas it ought to be 0.045 to 0.0625 ins in case of fine screen. It decides the minimum size of particle that will be rejected.
After fine screening the rejected stock may around 10-13%; it rejects such fibers that are not too coarse. Hence it may advise to rescreen the stock with the proper dilution to better recover. It may be a coarse screen. The accepted stock of fine screening is excellent quality for supply to the next stage.
The coarse screening removes the heavier particles such as very coarse fibers, knots, shives, dirt, and sand and it may be 4 to 5 percent of the whole stock. It may differ basis on kinds of fiber and type of screening and the diameter of the hole. The accepted stock of coarse screening is sent to the fine screening inlet side to rescreen for greater efficiency in the screening section.
Step 3: thickening of the pulp produced:
PULP THICKNERS
One of the types of pulp thickeners is a polydisc filter which is a combination of a number of plastic discs stacked on top of each other like a pile of poker chips. All discs are covered with small grooves. The discs (or rings) each have a hole in the middle, forming a hollow cylinder in the middle of the stack. The water passes through the small passages in between and the impurities are trapped behind. The filtration quality is based on the quantity and size of particles that the filtering element is able to retain. Higher quality filtration simply means cleaner water. This depends on the geometry of the channels, including the size, length, angle, and a number of generated intersection points. The discs are typically denoting the level of filtration. The typical range is from 25 microns for the finest level of filtration to 400 microns for the coarsest. Sometimes the filtration quality is given as the equivalent mesh size of a comparable screen filter.
Disc Filter is being cleaned with backflushed in such a way that the discs are able to separate and spin during the cleaning cycle. A booster pump is required for backflushing. Disc filters can be used for many types of contaminants, including fine sand and organic matter.
The mechanism for Poly Disc Filter operation: The face on each side of the disc has uniform sized grooves set at an angle to the rays of the circle. The cross-section of each groove forms an equilateral triangle. This cross section remains constant throughout the length of the groove. The diameter of the largest circle inscribed inside this triangular cross-section is the filtration size rating. When multiple discs are stacked and centered around a skeletal cylindrical structure called a spine, the discs form a hollow cylinder with the ends of the grooves exposed to both the inside and outside surfaces. When looking down on a single disc lying flat on a horizontal surface, the grooves on the top surface of the disc angle out and to the right of a ray to the circle. The hidden grooves, on the underside of this same disc, angle out and to the left of the circle's rays. This pattern forms numerous intersections of groove troughs and ridges along the length of each groove. The groove cross-section formed by any two adjacent discs will vary along the length of the groove. The change in cross-section causes turbulence in the flow. The flow stream and suspended particles move along the length of each groove following the sequence. A perfectly spherical particle smaller than the separation rating of the discs will pass through the filter without entrapment. However, most suspended particles are irregular in shape. The disc filter causes the flow stream cross-sectional pattern to oscillate while traveling along the length of the grooves. This mechanistic process is very effective in separating rigid suspended particles from a liquid stream.
Unlike two-dimensional separation devices that must possess openings that are physically smaller than the organic particles being targeted, disk filtration devices depend upon the process of particle/surface adhesion. Each particle that is trapped by a screen blocks nearly all of the flow through the trapping opening. Since the organic particles adhering to the groove surfaces of a disc filter can be relatively small compared to the groove cross-section itself, flow continues to go around the trapped particle carrying additional particles to adhere to other areas of the same groove.
This multiple entrapments of organic particles per groove gives this process the ability to continue three to five times longer between backflushes to build up the same differential pressure, given the same flow rate, than a two- dimensional screen. During the filtration process, incoming fluid surrounds the cylindrical stack of compressed discs and passes through the groove passages to the interior of the cylinder. Particles are removed from the stream as described above. Once inside the cylinder, the filtered fluid passes from multiple parallel stacked disc cylinders into a common manifold and out of the filter unit.
Step 4: Refining the pulp:
REFINERS
In stock preparation area of papermaking, refining is the most important aspect of the process, the characteristics of the cellulose fibers and the treatment as well as composition of the papermaking furnish comprise paper quality determined and it affects how the fibers are binding with each other during the formation of the paper web and the various optical, structural, and chemical properties of the paper will be.
There are two basic methods for pulp refining. An older system was a batch process, uses an oval tank called a beater. The beater is equipped with rotating metal bars that squeeze the fibers between stationary metal bars. The water-suspended fibers are repeatedly passed through the rotating bars, the fibers become frayed, shortened lengthwise, swollen in diameter and softened and the surface area is increased to facilitate the binding of fibers. Recently beater/refiner batch system has been replaced by continuous /batch disk refiners, which are rotating disks having serrated or otherwise contoured surfaces. One disk rotates clockwise, while the other rotates counterclockwise, or is stationary. The stock is pumped through the center of one of the disks and as centrifugal force throws the furnish toward the perimeter of the disks, it is pressed between them. The action of the rotating disks rubs, rolls, cuts, frays, and softens the fibers. The space between the disks can be adjusted, depending on the degree of refining desired. Refining is one of the critical process in paper engineering, the structure of paper and board as it has a major influence on fiber quality. Refining mechanically alters the fibers by brushing, hydrating, and cutting them.
During refining the fiber cell walls are delaminated, allowing them to absorb more water and increasing their flexibility. External fibrillation of the fiber surfaces increases the surface area available for bonding, and some fiber cutting and creation of fines takes place.
With the refining process, if fiber length is decreased, the strength and resistance to tearing of the paper produced will decrease, but the surface levelness and smoothness will increase, and the print quality will become better. As the degree of refining is increased, the density, hardness, ink holdout, smoothness, and the internal bond strength will increase, but thickness, compressibility, dimensional stability, and porosity will decrease. Other way increased refining will work to shorten paper fibers, which enhances smoothness and printability, but optimizes strength and resistance to stresses.
Step 5: preparing the paper from the refined pulp:
PAPER MACHINE
After beating/refining the pulp from stock preparation enters to the paper machine area and it passes through to the centricleaner, fan pump, pressure screens and enters to the manifold and then to headbox. The function of the headbox is to receive cleaned pulp stock at the consistency of 0.2-0.8 % and distribute it uniformly across the width of wire with a constant head. Rectifier / Evener / Holly rolls are used to provide necessary agitation and even out the distribution of fibers. Headbox is generally of two types, open head box, and pressurized headbox.
The prepared paper is only from the recycling of waste paper. It saves waste paper from occupying landfill which later produces methane as breaks down or degradation.
Although the field of the invention has been described herein with limited reference to specific embodiments, this description is not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments, as well as alternate embodiments of the invention, will become apparent to persons skilled in the art upon reference to the description of the invention.
,CLAIMS:We claim:
1. A composition of film face shuttering kraft paper comprising:
a recycled fibre extracted from steel mill kraft paper; and
a recycled fibre extracted from paper selected from New Double Lined Kraft Cuttings (NDLKC) and double-sorted corrugated containers OCC.

2. The composition as claimed in claim 1, wherein the recycled fibre extracted from steel mill kraft is in the range of 1-100%.

3. The composition as claimed in claim 1, wherein the recycled fibre extracted from paper selected from New Double Lined Kraft Cuttings (NDLKC) and double-sorted corrugated containers OCC is in the range of 1-60%.

4. The composition as claimed in claim 1, wherein the composition includes chemical mixtures.

5. The composition as claimed in claim 1, wherein the chemical mixtures are the mixtures selected from ferrous oxide along with wet strength resin, pigments, and resin.