Natural Ground and Precipitated

Calciumcarbonate in Woodfree Papermaking

Maximilian Laufmann

Abstract In this paper, GCC with its natural rhombohedral

particle shape is compared in a papermaking
Globally CaCO3 has become the dominant filler in environment with a typical filler PCC of
the production of woodfree uncoated paper and scalenohedral morphology (S-PCC). Although
coating base stock. other PCC morphologies are potentially possible,
this comparison is based on the globally most
CaCO3 fillers can be produced by specified common PCC particle shape for use as a paper
grinding of a natural CaCO3 deposit based on filler, i.e. the scalenohedral morphology. It is
chalk, limestone or marble. Ground limestone- or primarily this type of S-PCC, which can add
marble- based pigments are commonly named significantly to paper thickness.
natural Ground CaCO3 or GCC. Another
possibility of producing CaCO3 fillers represents In order to demonstrate the basic differences of
the precipitation of CaCO3 from CaO via Ca both types of pigment, used either separately or in
(OH)2 and CO2. Such a chemical Precipitation- combination in a paper filling application,
based CaCO3 product is termed PCC. For the uncoated woodfree paper with 80 g/m2 and 22 %
production of PCC, the step of burning natural filler loading was produced on a pilot paper
CaCO3 to CaO remains current industrial practice. machine. Only the type of filler was changed or
This means that both the GCC as well as the PCC the ratio of the fillers in the blend situation. All
manufacturing requires the availability of a other parameters where kept constant. The overall
suitable natural CaCO3 deposit. For PCC the basic results showed that natural ground CaCO3
choice is usually limited to limestone. produced easier drainage and drying of the paper
web, showed a lower size demand, a more closed
GCC fillers are by far predominantly produced in sheet structure and higher paper strength. Higher
a wet grinding process and delivered to the paper strength potentially allows for higher filler
papermills as ready to use slurries with high solids loading, always an interesting tool to reduce paper
contents of 65 to 72 %. PCC fillers are more cost. The GCC with higher fineness, while
commonly produced on-site at the papermill but exhibiting a relatively low specific surface,
there are also off site solutions. produced higher opacity vs. the standard GCC
filler.

The precipitated CaCO3 applied in this

Key words: comparison provided higher light scattering. In
comparison to GCC, the scalenohedral shaped
Fillers, Natural Ground CaCO3 GCC, Precipitated
PCC filler produced higher paper bulk. As a
CaCO3 PCC, GCC/PCC blends, uncoated paper,
consequence a distinctly more open sheet
coating base paper
structure was noticed. After calendering, the S-
PCC filled sheet showed a slightly lower PPS
roughness. Importantly, despite the disparity in
Maximilian Laufmann, paper bulk between the GCC and S-PCC loaded
Technical Service Manager papers, there was no difference in paper stiffness.
Rene Schneider,
Technical Service Commercial experience confirms the trends
Plüss-Staufer 4665 Oftringen Switzerland observed in the pilot study. The specific
individual situation and the choice of pigment
Phone ...41 62 789 2429 configuration strongly affects these tendencies.
Fax ...41 62 789 2358 Useful compromises offer the combination of
GCC and scalenohedral-PCC either as a ready- to- 1. Manufacturing Processes for GCC
use premixed product or each type of pigment
added individually via a dosage point into the
and PCC
paper machine system. Particularly less modern
The chosen selective micronisation process of
paper production units can exhibit drying capacity
natural CaCO3 from a deposit of chalk, limestone
limitations in the after drying section. In such
or marble is dependent on the final end-product
situations a combination of both pigments, GCC
application. World-wide a variety of mineral-
and S-PCC, is especially of advantage to the
ogical deposits can be used as GCC filler
papermaker.
pigments for the paper industry. In addition to
their mineralogical composition and, hence,
In coating base stock, GCC as a primary filler also
resulting pigment brightness, the logistical aspects
carries the potential of a faster draining and drying
in relation to the papermill are important and
sheet structure, compared to an S-PCC
crucial factors for the choice of a deposit.
application. This is particularly pronounced at
higher basis weights and higher primary filler
Based on the current high pigment brightness
loading levels. The GCC filled sheet usually
requirements, mainly marble or limestone-based
exhibits significantly higher internal bond values
raw materials are used for GCC filler pigments.
vs. the S-PCC loaded paper. This holds the
The pigment brightness can reach or exceed 95 %
potential of higher primary filler loadings at equal
Elrepho (R-457) depending on the raw material
internal paper bond. S-PCC produces higher base
quality and the individually adjusted production
paper bulk compared to GCC. However, this
processing. Micronisation is usually performed
higher bulk diminishes with calendering of the
using the so-called wet ground process.
coated sheet. After coating and printing, no
difference in terms of surface roughness, paper
and print gloss and print quality, initiated by the CaCO3 CaCO3
deposit coal, gas, oil CO2
deposit
choice of primary filler, has been noticed.
crushing crushing CO2
burning
Introduction grinding hydration
CO2
Over decades now, the desire for higher precipitation
screening screening
brightness and its strategic implementation in the
market place has been clearly observed. Despite CaCO3 CaCO3
GCC PCC
sporadic critical evaluation of the sense or
realistic need for this brightness trend, there has
been no halting influence on the market Figure 1
behaviour. GCC vs. PCC “Production Principles”

In comparison to kaolin qualities, calcium If necessary, impurities are mechanically or

carbonate fillers with their much higher pigment physico-chemically removed. Highly automated
brightness are important and have proven production processing and large production units
themselves as the main cost-saving option to are especially economic. The end-products are
improve the basic paper brightness. As a result of usually in the form of rheologically stable filler
this brightness asset and their world-wide slurries with a solids content from 65 up to 72 %.
availability, calcium carbonate fillers have GCC slurries dedicated to the paper coating
become one of the most important pigments in the industries are supplied today with solids contents
field of wood free paper grades. up to 78 %. A sophisticated logistics chain is a
vital component for the overall raw material and
Calcium carbonate fillers are today divided into paper product profitability. The slurry supplied by
two main categories; the natural ground CaCO3 - ship, railway or road transport is loaded into the
GCC and the precipitated grades of CaCO3 - storage tank of the paper mill and used today
PCC. The following presentation evaluates without any further treatments in the paper
closely both pigment types regarding their making process.
manufacturing process and specific properties as
well their application comparison in woodfree The manufacturing process of PCC fillers for the
uncoated paper as both single pigment and in paper industry also begins from a natural CaCO3
blends. Also highlighted are their properties as (figure 1). Due to some special technical aspects,
primary paper filler when used in coated paper the manufacturing process is confined to the use
qualities. mainly of limestone deposits. Additionally, the
2
selected limestone has to fulfil some basic 2. Applications - Natural Ground
mineralogical requirements. High manganese and
iron contents exemplify a very negative influence
CaCO3 and Precipitated CaCO3
on the brightness of the end-product. As a result
Morphological differences
of the original limestone quality, interactions can
occur which also negatively influence the optical Natural ground CaCO3 filler in its simplest form
and crystalline properties of the precipitated inherits from nature a rhombohedral particle shape
product. (figure 2). The morphology of precipitated
CaCO3, however, can be adjusted within certain
The above criteria mean that not every readily technical and chemical limits. These differences
available limestone deposit is an acceptable can lead to significant variation in the production
source for the manufacture of the essential costs of a PCC.
intermediary raw material, burned lime CaO,
needed in the PCC manufacturing process. A
stringent selection has to be made. As an example
of these severe restrictions, one on-site PCC
operation (on-site meaning PCC being
manufactured within the confines of the paper
mill itself) in South Africa is today forced, due to
limited availability of suitable local raw material,
to cover a part of their demand by sourcing from
Europe.
GCC S-PCC
The calcination of localised limestone to CaO
usually requires fossil energy. In the PCC Figure 2
manufacturing process, CaO is then further GCC and S-PCC Fillers
hydrated to calcium hydroxide Ca(OH)2. Burnt
lime reacts strongly exothermically in contact World-wide, the most common PCC particle
with water and Ca(OH)2, is highly alkaline. In one shape used in the paper industry is scalenohedral
or more reactors a re-carbonation with CO2 is (figure 2). Primarily, this structure is coupled with
made to produce chemically precipitated CaCO3, the property of giving the paper a higher bulk. If
PCC. The necessary CO2 gas can be gained from desired, particle shapes other than the
the on-site sulphate pulp line operation (limekiln) scalenohedron can be manufactured but are
or from the flue gases of the fossil-based paper coupled with higher technological requirements
mill's power station. It is also vital to consider not and additional costs. To simplify presentation of
only the availability of CO2, but also qualitative the following results, scalenohedral PCC is
parameters such as gas density, temperature, termed S-PCC (figure 2).
purity of CO2 etc. Therefore, gas-cooling and
cleaning systems for the CO2 have to be installed.
An additionally installed integrated storage 3. GCC and S-PCC in the Production
capacity for liquid CO2 is often needed to ensure of Uncoated Woodfree Paper
against temporary shortage of CO2. The control of
the particle size and fineness of the PCC quality is
3.1. Comparisons made on a pilot paper machine
made via monitoring of the precise reaction
parameters and the addition of specific reaction Trial conditions
additives. Such a PCC has after screening a
typical solids content of approximately 20 % and With the objective to compare both materials as
is stored on-site until usage. single pigment or in blends, trials have been
performed on a pilot paper machine. The
By so-called off-site PCC operations, the PCC emphasis of these trials were on the pigments
filler is shipped to the paper mill with a solids themselves and their direct and indirect effects in
content between 35 and 52 % and if necessary, the application including process as well as the
rheologically stabilised. PCC qualities in dry achievable paper quality.
powder form are also available in the market and
are mainly used in special paper grades. The working width of the pilot paper machine was
70 cm, the speed 80 m/min. The furnish: 25 %
pine sulphate (30 °SR) and 75 % birch sulphate
pulp (30 °SR). As sizing agent, AKD including a

3
promoter was used, at a dosage of 0.12 % A reduction of the S-PCC portion of the filler by
(dry/dry). A good retention of the filler and the inclusion of GCC in combination shows improved
sizing agent was achieved using a micro-particle drying results. Higher dry content leads to a
retention system, supported by additional 0.5 % positive development of higher initial sheet web
cationic starch. Following normal production wet strength.
conditions, a market-available anionic OBA (0.2
%) was also added (1/3 in the wet-end, 2/3 in the This trend, in respect of the dewatering after the
size press). The grammage was 80 g/m2 and the wire suction roll as a function of pigment choice,
adjusted filler content in paper set at 22 %. is confirmed by the values seen after the third
press (figure 5).
The specific pigment data corresponding to the
filler grades used are listed in figure 3. The GCC
used, 60/7.0, i.e. 60 % < 2 µm with a specific % Dryness after 3rd press
51
surface area of 7.0 m2/g, is a European standard GCC (% < 2 µm)
50 60 85
quality from a marble resource. The GCC grade,
85/7.5, (85 % < 2 µm, 7.5 m2/g specific surface) 49
also from a marble-based source, is designed to 48
develop a higher paper opacity in comparison to a 47
standard GCC. 46
100 75/25 50/50 25/75 100 0
GCC GCC S-PCC GCC Blends S-PCC
60 / 7.0 85 / 7.5
Spec. surface
BET m²/g 7.0 7.5 6.5 Figure 5
Sedigraph fineness Drainage
< 2 µm % 60 85 45
< 1 µm % 35 60 15
The effect of this slow-down of dewatering with
aps µm 1.5 0.8 2.1
S-PCC as filler can be at least partly explained by
Brightness % 94.5 95.0 95.5
R-457 a more voluminous structure of the pigment and
the paper formed out of it. A higher bulk mass
requiring subsequently higher drainage power. If a
Figure 3 PCC with a prismatic structure had been used, the
Pigment Data dewatering behaviour would therefore be
positively influenced as seen with a GCC, but, as
The quality of the S-PCC used in these trials
a result, such a product, compared to GCC, would
represents a typical S-PCC filler commercially
not give a higher paper bulk. With a higher
available from an on-site production unit. All 3
content of S-PCC in the blend, or with 100 % S-
filler pigments show a high pigment brightness of
PCC, a drastic increase in size press pick up is
approximately 95 % Elrepho R-457.
observed at the conventional size press.
3.2. Papermaking process
l/min Starch / Polymer
As shown in figure 4, the usage of 100 % S-PCC 3.0
GCC (% < 2 µm)
displays a clearly lower dry content after the wire 2.8 60 85
suction roll compared to 100 % GCC. 2.6
2.4
% Dryness at couch roll 2.2
30
GCC (% < 2 µm) 2.0
29 60 85 100 75/25 50/50 25/75 100 0
28 GCC Blends S-PCC
27
26 Figure 6
25 Size Press - Pick Up
100 75/25 50/50 25/75 100 0
GCC Blends S-PCC The origin of this phenomenon is surely due to the
higher paper bulk and open, more porous, paper
Figure 4 structure coupled with a higher paper humidity
Drainage leading to a lower sizing development before the
4
size press. On the occasion of a different GCC/S-PCC blends up to 100 parts S-PCC, are
investigation on the same pilot machine regarding both nearly linear. S-PCC, in the form of single
an organic filler to achieve extra high paper bulk. particles of filler, gives, in comparison to GCC, a
A significantly higher pick up of starch in the size higher bulk.
press similar to S-PCC was obserbed.

Due to the technical equipment available on the cm³/g

1.5
pilot machine the steam demand in the pre-drying GCC 85 % < 2 µm
1.4
section unfortunately could not be recorded, but
only in the post-drying section. Trials including an 1.3
15 kN/m
increased S-PCC portion of 50 % or more in the 1.2
sheet web showed much higher steam demand. 1.1
30 kN/m

1.0
100 75/25 50/50 25/75 100 0
kp/cm² GCC (% < 2 µm)
2.5
60 85
GCC Blends S-PCC
2.0
1.5
Figures 9
1.0 Bulk
0.5
0.0 This creates in the paper, through further inter-
100 75/25 50/50 25/75 100 0 particle flocculation, a relatively high voluminous
GCC Blends S-PCC structure. The resulting separation between the
paper fibres increases and thereby paper thickness
and bulk are increased. It could be possible that
Figure 7
chemical and physical parameters of PCC are
Steam Demand after Dryers
influencing additionally the mechanistic
development of paper bulk.
The simple explanation for this follows the
comments already made regarding higher starch
Importantly, however, the higher paper bulk
demand in the size press with high amounts of S-
generated by an S-PCC pigment is not
PCC in respect of increased pore bulk.
automatically leading to a measurable increase of
paper stiffness (figure 10). A research of market
3.3. Paper quality
paper confirms this latter observation.
The production of the paper in the pilot machine
was finished by passing the sheet through a
machine calender. The calender pressure was mNm Resonance L x Q²
0.5
adjusted to 15 and 30 kN/m, respectively. When GCC 85 % < 2 µm
using S-PCC as single filler or in a blend with 0.4
GCC, higher paper thickness together with higher 0.3 15 kN/m
bulk are noticeable. 0.2 30 kN/m
0.1
µm GCC (% < 2 µm)
0.0
110 100 75/25 50/50 25/75 100 0
60 85
105 GCC Blends S-PCC
100
95
Figure 10
90 Stiffness
85
100 75/25 50/50 25/75 100 0
The expectation that it might have been possible
GCC Blends S-PCC when using an S-PCC, arising from the resulting
higher paper bulk, to reduce the grammage from
Figures 8 80 down to 75 g/m2 and maintain the paper
Thickness thickness has not been fulfilled. A reduction of the
grammage especially in this specific range leads
The increase of paper thickness and bulk, in these to a drastic loss of paper stiffness and, naturally,
trials starting from 100 parts GCC through lowers the opacity significantly.

5
 the papermaking process are more densely
mNm Stiffness (Resonance)
0.45 consolidated and therefore disturb less the fibre-
without Filler
0.40 with GCC 60/7.5
fibre bond.
0.35
Based on results of a lab study the tensile strength
0.30
decreases when an average S-PCC particle size of
0.25 approx. 2 µm is exceeded. Noticeably, S-PCC
0.20 grades of lower fineness, used to create highest
65 70 75 80 85
paper bulk, are exhibiting high dusting tendencies.
g/m² Basis Weight
A well-known problem in the copy machine.

Figure 11 The larger fibre-fibre separation generated by an

Stiffness vs. Basis Weight S-PCC results, in comparison to GCC in higher
paper porosity.
It is also clear, that it is apparently necessary to
set a standard minimum of 80 g/m2 to provide a
ml/min. Bendtsen GCC (% < 2 µm)
trouble-free handling in European copy machines 1400
60 85
(given the higher filling rates in comparison to 1200
North America). This can also be connected with 1000
these findings.
800
600
The resulting S-PCC induced increase in
separation between the single inter-fibre and fibre- 400
100 75/25 50/50 25/75 100 0
floc connectivity leads consequently to a
GCC Blends S-PCC
reduction of the occurrence of H-bonding and,
therefore, to a reduced paper strength.
Figure 13
Porosity Bendtsen
N MD GCC (% < 2 µm)
85
60 85 Through combinations/blends of S-PCC and GCC
80
the porosity can be positively influenced, i.e. the
75 paper surface can be made more closed. Normally
70 in practice, the porosity of the paper structure is
65 effectively adjusted via further fibre refining
60 which of course is coupled with additional energy
100 75/25 50/50 25/75 100 0 costs. Associated with the additional energy
GCC Blends S-PCC demand of stronger refining is also an increased
hygroscopic sensitivity of the fibres and so also of
the paper.
Figure 12
Tensile Recently, in Asia, a new large production line of
wood free base sheet went into production. Today,
The resulting difference in tensile strength the furnish is a mix of tropical hardwood but it is
between 100 % S-PCC and 100 % GCC 60/7.0 is planned in the near future is to use a fast-growing
highly significant; GCC 85/7.5 also shows in acacia.
comparison to GCC 60/7.0, a lower tensile. This
is explained by the greater fineness of GCC 85/7.5
compared to GCC 60/7.0. Tropical Hardwood vs. European Birch
Bulk + 20 %
Though not demonstrated specifically here, but Brightness + 4 % points
known from former lab and practical tests, there is Opacity + 1 % point
a significant difference between GCC and S-PCC Light scattering + 15 %
regarding the influence on the paper internal bond Tensile - 30 %
(Scott bond). The usage of S-PCC as filler leads, Internal bond - 50 %
in comparison to a standard GCC product, to a Porosity + 30 %
significantly lower internal bond. The higher Scott
bond with GCC can be explained as a result of
GCC's broader particle size distribution curve. Figure 14
The flocculated GCC aggregates formed during Tropical Hardwood vs. European Birch
6
These pulps are showing, in comparison to a darker fibre is better hidden. Negatively
standard European fibre mix, a naturally higher influenced by an increased S-PCC amount in
bulk and significantly higher light scattering. these trials is the CIE brightness.
Indeed the tensile strength and Scott bond are
comparatively much lower and the porosity higher
(open paper sheet). Based on these technical % GCC (% < 2 µm)
145
60 85
aspects and on the wish of highest possible filling 140
ratio this paper maker chose GCC as filler so as to
135
retain advantage of the natural bulk of the fibres
130
without destroying the paper strength.
125
The values in figure 15 relate the influence of 120
100 75/25 50/50 25/75 100 0
pigment on roughness of the paper surface. With
an increased amount of S-PCC a trend to lower GCC Blends S-PCC
roughness can be observed. Comparing 100 parts
S-PCC to 100 parts GCC, the difference ranges Figure 17
from between 0.5 to 0.8 µm, measured with the CIE Whiteness
Parker Print Surf. No significant influence of
these measured roughness differences on a print One explanation is to be found in the different
sample could really be detected. type of charge of the pigments and their
interaction with the anionic optical brightener.
µm PPS
Both GCC qualities were anionic wet ground
6.5 produced, while PCC showed a slight naturally
GCC 85 % < 2 µm developed cationicity.
6.0
5.5 15 kN/m
As an effect of the particle structure, and a steeper
5.0
30 kN/m
particle size distribution curve, S-PCC shows the
4.5 expectedly higher light scattering effect. This
4.0 higher light scattering effect is the basis for
100 75/25 50/50 25/75 100 0
influencing positively the paper opacity.
GCC Blends S-PCC

m²/kg GCC (% < 2 µm)

Figure 15 70
60 85
Roughness PPS 65
60
As already mentioned, all three fillers showed a
similar pigment brightness of 95 % with Elrepho 55
R-457. The brightness differences measured in the 50
manufactured base sheet are therefore minimal. 45
100 75/25 50/50 25/75 100 0
GCC Blends S-PCC
% GCC (% < 2 µm)
90 60 85
89 Figure 18
88 Light Scattering
87
86 % GCC (% < 2 µm)
93
60 85
85
100 75/25 50/50 25/75 100 0 92
GCC Blends S-PCC 91
90
89
Figure 16
Brightness R-457 - UV 88
100 75/25 50/50 25/75 100 0
GCC Blends S-PCC
The very slightly higher brightness with S-PCC in
comparison to GCC is mainly due to its
comparatively higher light scattering coefficient Figure 19
as a function of filler-fibre voids. The slightly Opacity at 80 g/m²
7
Also with GCC the light scattering effect can be these remaining traces of Ca(OH)2. Under
influenced via increased particle fineness and specified shear stress conditions and nitrogen
steeper particle size distribution curve, to improve saturation this source of alkalinity (out of the
paper opacity. This is demonstrated by GCC crystal core) can be made evident.
85/7.5. Also presented are the results with the
blend of GCC/S-PCC. Also, in association with this evolution of
alkalinity, a sizing loss (size reversion) over a
As extensively described in the relevant literature, certain time period must be recognised. To
sizing with AKD is often coupled with difficulties minimise this risk, generally in paper production
when using S-PCC. This phenomenon could also right from the beginning, higher amounts of AKD
be noticed in these trials. As presented in figure are added. Analytical analysis of PCC filled
20, at a given dosage of 0.12 % AKD (dry/dry) papers confirm higher quantities of hydrolysed
with even just 50 % S-PCC, there results a totally AKD (ketone).
insufficient sizing of the paper.
3.4. Summary of the trials on the pilot paper
g/m² Cobb (60) 0.12 % AKD machine
60

50
GCC S-PCC
g
sizin
40
Brightness Brightness
30 no Drainage Caliper
20 Dryness Bulk
100 75/25 50/50 25/75 100 Strength Light scattering
GCC Blends S-PCC Density Roughness
Sizing

Figure 20
Sizing Figure 22
GCC vs. PCC “Criteria’s”
In a following trial made under the same
conditions, a 50 % higher AKD demand was Both filler types GCC and S-PCC are suitable to
necessary to reach the desired sizing. The primary provide a high base sheet brightness. The natural
reason for such a high AKD demand is to be rhombohedral GCC leads to comparably easier
found in both the higher paper humidity of the dewatering and drying of the sheet web. On the
sheet web when entering the pre-drying section as other hand S-PCC provides a significantly higher
well as the remaining quantity of Ca(OH)2 when paper bulk. This higher paper bulk, however, does
using PCC. At high temperature and high not automatically leading to additional paper
moisture levels the reaction between AKD and stiffness. GCC as filler reduces the paper strength
water (hydrolysis) is very strong. This hydrolysis less than S-PCC. This gives an advantage with
of AKD is additionally supported by the GCC for higher filling levels and the associated
remaining traces of Ca(OH)2 (alkaline). savings. The specific structure of S-PCC and the
steep particle size distribution curve provide this
pH pigment with a high light scattering coefficient for
13
good opacity. GCC 85/7.5 also with its increased
12 S-PCC slurry fineness and steeper particle size distribution
S-PCC powder
11
curve shows, in comparison to GCC 60/7.0 a
higher light scattering coefficient and provides
10 S-PCC slurry higher paper opacity. A paper with GCC as filler
9
GCC compared to S-PCC shows a significantly lower
paper porosity. The paper produced with S-PCC
8 has, after calendering, a lower surface roughness.
0 30 60 90
Shearing min. It has to be mentioned that no noticeable
differences could be found on printed samples
Figure 21 related to this lower surface roughness.
GCC / PCC and pH
Due to the rhombohedral particle structure and the
The higher pH values typically seen when using resulting better dewatering/drainage properties, as
PCC in comparison with GCC are generated from well as improved pH stability, the demand of
8
sizing agent is lower with GCC compared to S- required a 20 % increase of energy demand. With
PCC. a filler combination 50 % S-PCC / 50 % PCC the
customer went back to the original machine speed
The combination of both pigment types in and could reduce also the required fibre refining
different ratios allows a fast and flexible (figure 23).
adjustment for the required paper quality. The
specific optimal pigment ratios to achieve defined At identical smoothness levels the paper thickness
quality parameters can be easily fine-tuned. decreased only by 2 µm and the opacity by 0.5 %.
With this pigment formulation an increase of
3.5 Notes from the field paper strength of nearly 10 % was obsered. In
Europe, huge amounts of copy paper with a filler
The tendencies noted on the pilot paper machine
load up to 28 % are produced and absorbed by the
have been confirmed on several occasions on
market. An analysis of this paper, shows a
existing production lines. The basic differences
successful implementation of 100 % GCC.
generated by the pigment are mainly dependent on
the respective technical conditions. Considering
that the aim is to produce marketable paper 4. GCC and S-PCC as Primary Filler
quality, direct pigment comparison is heavily in Woodfree Coating Base Paper
influenced by several necessary correcting
measures in practice. As a matter of fact, the new Major properties required for a woodfree coating
huge production machines are mostly having base paper are sufficient tensile strength, good
sufficient drainage and drying capacities built-in. internal bond (Scott bond) as well as a stable
A potential bottle-neck in the post-drying section water absorption and wetting properties at high
is mainly to be found in older production units. dimensional stability. High brightness and
acceptable opacity are simply a must with a closed
A combination of S-PCC (higher paper thickness) surface being considered of great advantage.
with GCC is, when facing insufficient drainage Pigment ratio including primary and secondary
and drying capacities, of great advantage. filler is, depending on the grammage, at a level of
about 12 to 20 %.
With such an alternative, the papermaker obtains a
high paper bulk and high strength. The demand of In a specific trial on the pilot paper machine an 80
AKD is kept on normal levels and the production g/m2, coating base paper was produced. As
speed corresponds nearly to an operation using primary filler, 8 and 12 % GCC and S-PCC,
100 % GCC. respectively, were compared. As a result of the
addition of coated broke, the amount of secondary
pigment in the coating base paper was 8 %. Using
( + = improved ) S-PCC GCC/S-PCC
a compromise between double coating and single
coating practice, a single coat of 15 g/m2 per side
Refining Demand O (+) of coating colour was applied with bent blade.
Drainage O ++ The coated paper was afterwards calendered and
PM Speed O ++ offset printed. The results of this trial can be
Bulk O -
CIE Whiteness O + summarised as follows.
Opacity O -
Stiffness O O
Roughness O - Pilot und Commercial :
Burst O +
GCC Drainage, Strength
S-PCC Bulk prior to calendering
Figure 23
GCC /. S-PCC Blends (com. experience) After coating and calendering
GCC vs. PCC
s
Roughness, ce
A typical experience relating to this (figure 23: a ren
Paper- / Print gloss, fe
European paper manufacturer made several trials Print quality dif
no
to produce a high quality 80 g/m2 copy paper
using 100 % S-PCC of different origins on a
Fourdrinier machine. The customer saw that Figure 24
dewatering became distinctly worse and GCC and S-PCC in Coating Base Paper
consequently had to reduce PM speed by about 10
%. Additionally, the open paper structure could Again, the GCC filled paper showed higher
only be closed by higher fibre refining which favourable drainage properties of the sheet web.
9
Also the internal bond (Scott bond) was, with a
standard GCC, significantly higher. As expected,
the coating base paper produced with S-PCC as
primary filler showed higher bulk, a property
which after calendering of the coated paper was
no more visible.

Basically, it can be stated that after coating and

calendering no significant differences regarding
roughness, paper and print gloss as well as
printability could be detected. What was
influenced, however, were the optical properties
of the coated paper by those of the coating base
paper (being generated by the filler).

In practice, using GCC as primary filler is of

particular advantage in papers of higher
grammages. The reason behind this is mainly the
better dewatering and drainage properties and, as
already mentioned, the higher Scott bond with this
filler. Higher and better drainage gives the
possibility to increase production speed. The
higher Scott bond with standard GCC will allow
basically a higher filler loading. High filling levels
positively influence opacity and brightness of the
paper.

At the same filler content, a paper with S-PCC as

primary filler will, due to the higher light
scattering coefficient of the pigment, have a
higher opacity in comparison to one with a
standard GCC. The difference is mainly
dependent on the added amount of primary filler.
A GCC 85/7.5 filler will lead to similar paper
opacity as when using less finer S-PCC grades.
The combination of standard GCC and S-PCC as
primary filler in woodfree coating base paper is in
the US not unknown. A close look at the pigments
from the coated broke together with S-PCC
primary filler are already showing the
combination GCC/clay/S-PCC.

Conclusion
Both, the pilot and commercial examples illustrate
the important attributes of GCC and S-PCC. They
are very different in performance and therefore
provide a wide range of options for producing
papers with various end-use demands. GCC
provides strength and higher loading potential,
easier drainage and drying, low size demand, and
higher sheet density. PCC provides higher opacity
at lower filler loadings and lower density (higher
bulk). In this way, papermakers can choose the
attributes necessary for a particular grade. Both
type of pigments provide high brightness at a low
cost.

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