Operation: New York, 100% Post Consumer Recycled Furnish
Machines: Fourdrinear with Yankee dryer
Grade: Producing Brown Towel, Napkin, tissue & Specialty Grades
Furnish: DLK, Ledger, Mixed Furnish, News, Core Stock, Sludge
Mill wanted to increase production and reduce chemical costs (Polymer stickies treatment & solvent table/felt washes). Higher machine speeds resulted in excessive deposition, increased sheet breaks and more solvent use. Machine efficiency and product quality suffered.
Mill engineers felt the Stock Preparation System was acceptable and only a more effective stickies control program was required. They also believed the operation could operate using lower cost furnish.
ENESSCO Technology was initiated as a Fiber/Contaminants "Modification" Treatment. This approach actually treats the surface interface between the contaminant and the paper fiber. ENESSCO allows the contaminants to "independently" release from the wood fiber. The contaminants are stabilized and are more efficiently removed by Screening & Cleaning equipment.
100% concentrated dry ENESSCO product was fed to the neutral pH pulper at 0.9 lb./ton. ENESSCO is administered via repulpable bags to the pulper. Detac stock treatment was eliminated.
ENESSCO treatment resulted in a production increase of 6% on the machine. Stickies deposition was virtually eliminated and enabled the mill to eliminate solvent use. The substitution of ENESSCO for the Detac chemical reduced stickies treatment costs from $5.00/ton to $3.00/ton. Wet Strength use was also reduced.
ENESSCO also improved final sheet quality. "Dirt Counts" related to stickies and other contaminants were reduced from 25%-50% depending on the recycled furnish used. This enabled the mill to reduce furnish quality. DLK was cut back, while MOW, Core Stock, and ONP were increased. Alternative furnishes were also investigated. ENESSCO has enabled the mill to use off-site Sludge (10% furnish substitution) to substantially reduce operating costs.