01/10

Magazine for the paper industry

XX New Competence Center: Eco-friendly and

sustainable product design
XX Fibre modification opens up new ways to save
energy
XX How long do inkjet prints retain their colour?
XX Informative and practically relevant results
about anaerobic biodegradability

XX Successful water circuit optimisation at Sappi

Maastricht and Hamburger Rieger
XX Using PTS models for web-based simulation
and optimisation
XX PTS soft sensor Virtual fractionation now
available as demo version
XX First round robin test of DOMAS Version 3.0

www.ptspaper.de

PTS News 01/2010

contents

Under spotlight
A New PTS presents itself. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
New Competence Center: Eco-friendly and sustainable product design. . . . . . . . . . . . . . . 5

Research
Fibre modification opens up new ways to save energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
How long do inkjet prints retain their colour? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Customer projects
Informative and practically relevant results about anaerobic biodegradability. . . . . . . . 10
Successful water circuit optimisation at Sappi Maastricht and Hamburger Rieger. . . . . 13
New technologies for papermaking and pulp upgrading at the pilot plant
in Heidenau . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Using PTS models for web-based simulation and optimisation . . . . . . . . . . . . . . . . . . . . 16
PTS soft sensor Virtual fractionation now available as demo version. . . . . . . . . . . . . . 18

Testing
New IR spectrometer broadens range of paper and raw material analyses
offered by PTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
New paper-analytical methods based on Raman spectroscopy . . . . . . . . . . . . . . . . . . . . 19
First round robin test of DOMAS Version 3.0 and DOMAS ScannerAdvanced . . . . . . . . . 21
Fast and efficient quality testing of Braille on pharmaceutical packaging now via
the Internet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Imprint
Publisher

Papiertechnische Stiftung (PTS)

Hess-Strasse 134, DE-80797 Munich

Editor/Layout

Erwin Polmann

Mail: erwin.polmann@ptspaper.de
Translation

Corina Schmidt

Bryant McEwen

Title image:
Paper reel, PTS Pilot Coater VESTRA, Munich

PTS News 01/2010

Under spotlight

A "New PTS" presents itself

Against the background of major changes in the paper industry, Papiertechnische Stiftung started to discuss its strategic realignment in December 2008.
The discussion process involved both the upper management and a large number of young PTS employees. It was
completed by extensive information from a survey conducted among numerous companies from all segments of the
paper chain.
The result of these discussions was a new strategic orientation of PTS. Logically, this called also for a new organization which came into force on 1 February 2010. So what
has been changed and which chances and benefits do these
changes offer to companies in the paper industry?
Partner for the industry
Customers are a key issue. PTS sets great store being a partner for the entire value chain ranging from wood as the
main raw material via the production of pulps, paper and
board to the upgrading and converting of papers to obtain
marketable products. This is also laid down in our statutes.
It goes without saying that supply industries constitute an
essential part of this value chain as well. Whats really new
and goes beyond our previous aims is that PTS is now also
open to co-operation with other sectors offering increasing
synergies or new application areas for fibre-based products.
Examples of sectors PTS is planning to get increasingly involved in at least in certain areas and via partnerships - include the woodworking and panel industry, printing sector,
the automotive and the ceramics industries.
Strategic realignment
To serve the pressing needs of our target sectors, issues of resource management, innovative fibre products and surface
finishing have been brought to the fore. Our service portfolio is supplemented by projects dealing with the ecological
relevance of products and processes. Two aspects have been
brought together and are given particular attention:

1. 1) The value chain of PTS: publicly funded research and

development build a knowledge lead which can then be
transferred to industry to resolve the questions of our
customers on the highest scientific level.
2. 2) The value chain of the paper industry: reflecting the
mutual integration and interdependence of processing
steps, the various components of PTS knowledge have
been integrated into Competence Centers to make them
applicable to all sectors.
In detail, the new Competence Centers will focus on the
following topics:
Overriding issues of the Competence Center Resource Management (CCR) are raw material availability, competitive
uses and cascading utilization systems (of especially wood
and recovered paper) as well as complementary utilisation
options using bio-refineries. This is supplemented by issues
of water and energy use. Focal points are the efficient and
sustainable manufacturing and converting of paper products and comprehensive use of all materials generated by
the manufacturing process.
The already high demand for expertise leading to environmentally compatible, health-friendly and sustainable product and process designs is going to increase even further
in future. To professionally serve our value chain in this
respect, we have established the new Competence Center
Environmental Relevance (CCU).
Innovative composite materials are a future issue concerning nearly all sectors. We see great chances for new applications based on combinations of cellulose fibres with
other materials. The Competence Center Fibre Composites
(CCF) will deal with these issues, focusing on fibre technology and functionalized products. The fibre technology
pilot plant in Heidenau provides the technical facilities for
efficient developments in this area.

demand

Ccientific methods

knowledge
generation

knowledge
transfer

companies of the
paper chain

Resources

Contract research

Paper producers

Fibre compounds

Consultancy

Paper converters

Surfaces

Training

Supply firms

Ecological
relevance

Material testing

other....

Pilot plant facilities

Co-ordinated with the demand of the paper industry, PTS is generating innovative knowledge in
its research work that is transferred back to industry by services.

The Competence Center Surface Finishing (CCO) has a similar structure,

including the two departments surface technology and functional surfaces. Apart from traditional methods
and products, it focuses especially on
new applications based on functionalized paper products. The VESTRA
pilot coater serves as an important pilot plant facility for this competence
center.
We need new and improved scientific methods to increase the innovative level of our research projects and

PTS News 01/2010

President

Public relations

Research
controlling

Under spotlight

Research

Organisation of
training events

Finance

Fibre compounds

Surface
finishing

Resources
management

Ecological
relevance

Methodology

Testing/
Expert opinions

Fibre technology

Surface
technology

Raw materials
and biorefinery

Impacts on
environment

Design and
simulation

Material
testing

Functionalized
products

Functionalized
products

Treatment
processes

Product design

Sensorics

Testing and
calibration service

Fibre and
paper pilot plants

Pilot coater
VESTRA

Energy and
water use

services derived from them. For this purpose, we are going

to establish a new Competence Center Methodology (CCM)
in the next few months. Design, modelling, simulation and
online sensor technology will be the cornerstones of the
new CCM. Moreover, we are going to increase our activities
in the field of special analyses.
Organisation
Publicly funded R&D, contract R&D and consultancy have
been integrated into the Competence Centers in the new
PTS structure. This will enable us to make all our competencies optimally available and act more openly both internally
and externally. Competences currently not available at PTS
will be provided by intense and targeted networking, which
will considerably broaden the technical spectrum of PTS.
The paper research cluster CPF (Cluster Papierforschung)
is one example of such networking: PTS scientists develop
and perform co-ordinated projects in close co-operation and
on an equal basis with other German research and university institutions.
The new organisational structure will also further change
the image of our working methods conveyed to the outside. Publicly funded research and direct customer projects
will represent a value chain our target industries can benefit
from more than before.
In publicly funded R&D projects, PTS scientists generate
pioneering knowledge which is available without limitation
to any company - in particular to small and medium-sized
enterprises. On this basis, PTS can be a competent partner for company-specific tasks like product development,
process improvement, troubleshooting, system analysis,
handling of complaints etc. Naturally, the contract research

PTS 2010

results obtained for individual companies are treated as

strictly confidential. The fact that PTS can draw on pioneering knowledge gained by research to offer innovative solutions is a unique characteristic no other consulting company
is currently able to offer. Furthermore, the close connection
between pioneering knowledge and application has positive
effects on the definition of research subjects. Projects are
only realized if there is a documented need and interest of
companies from the paper chain. This ensures also a closer
co-operation with our customers.
Conclusion
As New PTS we can now present ourselves to the industry with greater strength and focus. We can offer our customers any competence they need to tackle future tasks. As
a professional partner, we will be actively involved in their
activities to contribute significantly to their efforts. Make
use of our services we stand ready to assist you!

Contact
Dr. Frank Miletzky
0049 89 12146 184
frank.miletzky@ptspaper.de

PTS News 01/2010

Under spotlight

New Competence Center: Eco-friendly and

sustainable product design

The already high demand for research, development and

expertise leading to environmentally compatible, healthfriendly and sustainable product and process designs is going to increase even further in future.
PTS has therefore established the new Competence Center
CCU Eco-friendly and sustainable product design. Direc
ted by Ms Ingrid Demel, the new Competence Center will
work intensively to resolve issues of sustainability and environmental compatibility.
The focal points of its work are listed in the table. Environmental effects and the substances present in recovered paper,
paper and packaging products are at the forefront. Certain
issues will be dealt with in close co-operation with other institutes, laboratories and consulting companies. Internal and
external networking is therefore of paramount importance.

The work of the new Competence Center is expected to

bring the following benefits to the industry:
Reducing possible impacts of the manufacture and converting of paper and packaging products on the environment and human health
Developing competitive products with particular emphasis on issues of sustainability

Contact
Ingrid Demel
0049 89 12146461
ingrid.demel@ptspaper.de

Research and
development projects
Environmental effects
Water footprint
Carbon footprint
Eco-balancing
Life cycle analysis
Socio-economic issues
Eco-labelling etc.
Cost calculation of environmental impact
Trace substances in emissions
REACH/chemicals safety
Environment- and health-friendly, sustainable product design (paper and packages)
Recyclable, deinkable
Eco-friendly and sustainable
Health-friendly
Food safety (Recommendation XXXVI)
Formulations (chemicals, nanoparticles, fibres, ...)

Contract R&D,
consultancy, studies,
analyses

TTraining,
in-house courses

PTS NEWS 01/2010

Research

Fibre modification opens up new ways to save energy

The following modification options were used instead of

refining:
attachment of carboxymethyl cellulose (CMC),
alternating, multiple coatings using cationic and anionic
polyelectrolytes (PEM Poly-Electrolyte Multilayer)
addition of micro-fibrillated cellulose (MFC) and
a combination of these measures to achieve synergetic
effects.
As already reported in the PTS News issues 2/2009 and
3/2009, fibre modification can produce strength properties
almost equal to those achieved by refining. This applies especially to hardwood pulps, where modified refining can
at best save up to ~200 kWh/t pulp (specific refining energy). In softwood pulps, the strength properties achieved
by modification corresponded to those obtained by refining
using between 50 and 100 kWh/t pulp.
Why modifications of fibre surfaces can be substituted for
refining is obviously due to the colloid-chemical interactions reaching practically all fibres as opposed to refining,
the mechanical treatment of which acts only on part of the
fibres. The treatment results of and damage to individual
fibres will therefore vary more in refined pulps compared
to modified pulps.
This leads to a second, no less important effect of modification: Because refining is omitted and fibres are modified
more uniformly, the drainage resistance remained on the
level of unrefined, unmodified pulp. The drainage rate of
modified pulps is therefore almost the same as before the
modification. The effects observed for water retention values (WRV) were even more favourable: Water retention is

50
45

Tensile Index [Nm/g]

In a pre-research project (IW VF 080012) PTS scientists investigated - among other - to what extent it is possible to
replace pulp refining by fibre modification. They elaborated
a concept how to develop paper strength by nano-technological fibre modification and the formation of nano-fibre
composites instead of refining.

Refining

40

Refining
CMC
PEM 1
CMC + PEM 1
PEM 2
CMC + PEM 2

35
30
25
20
15
10

unrefined and
unmodified BEKP

5
0

50

100

150

200

WRV [%]
Fig. 2. WRV development by refining and by the various modification
options of unrefined, bleached eucalyptus pulp (BEKP).

a parameter characterizing to which degree water can be

removed from the pulp by mechanical dewatering on the
wire and in the press section of a paper machine and which
percentage of the water can only be removed by drying.
Fig. 1 shows how the WRV of a pulp influences the energy
demands of mechanically induced dewatering and of drying. The lower the WRV, the more water can be removed
from the pulp by mechanical action. The example in Fig. 1
illustrates that it is possible to mechanically dewater a pulp
having a headbox consistency of 1 % and WRV of 122 % to
a consistency of around 45 %. Approximately 97.8 t of the
99 t water introduced per t of pulp at the headbox can be removed by mechanical dewatering. Approximately 1.14 t of
the remaining 1.22 t water/t pulp must then be evaporated
in the drying section of the paper machine to achieve a final
dry content of around 92 % in the paper.
The example shows the enormous savings made possible
by WRV reduction when using the tensile strength index
achieved as a basis for comparison. An increase in WRV was
observed only for the pulp modified with anionic CMC, but

1000000

300
blue: consistency achievable by mechanical
dewatering at the pulp property WRV

250

10000

200
red: water in pulp/paper
for a defined consistency level

1000

150
122

100

WRV Fibres [%]

Water content pulp / water

[kg H2O/t fibres]

100000

100

10

1
0

1,0

10

20

30

50

water removal
by drying

mechanical dewatering
on wires and by pressing

40 45 50

60

Consistency [%]

70

80

90 92

0
100

Fig.1. Influence of WRV on the energy consumption of mechanical dewatering on

wires and by pressing

PTS News 01/2010

Research

even in this case the value remained below that achieved by

comparable refining. All other modifications completed by
a cationic polyelectrolyte in the PEM coating step showed a
decrease in WRV. The increase in tensile strength could be
separated from the development of WRV (see Fig. 2). The
resulting saving potential is obvious - similar to the example
in Fig. 1.
The studies have shown that in addition to saving refining
energy, fibre modification can drastically reduce the energy
demand for dewatering and drying, especially if several
modification options are combined and the uniform treatment of all fibres is ensured.

Contact
Dr. Klaus Erhard
0049 3529 551 627
klaus.erhard@ptspaper.de

How long do inkjet prints retain their colour?

The objective pursued in one PTS research project was to investigate the ageing behaviour of coloured inkjet prints under
realistic environmental conditions. The results will be presented in a two-part article. The first part focuses on ageing
behaviour under realistic envonmental conditions.
In the past few years, inkjet printing has evolved into a successful competitor with electrophotographic methods. This
success is due, among other things, to the fact that the printing process is comparatively simple and has high potential
for development both economically and ecologically. Inkjet
printing, especially in the production of coloured prints, has
made inroads into high-grade applications that up to now
have been reserved for laser printing.
Within the scope of research project IW 061085, PTS developed a test procedure for the accelerated light-induced
ageing of inkjet prints based on studies conducted on the
ageing behaviour of coloured inkjet prints under realistic environmental conditions. The project was funded by
project sponsor EuroNorm GmbH appointed by the Federal
Ministry of Economics and Technology. The first part of this
article is devoted to discussing ageing phenomena under realistic environmental conditions which laid the foundations
on which the test procedure was subsequently developed.
The next issue of PTS News will present the results of simulated accelerated ageing.
Ageing under realistic environmental conditions
The studies were based on prints made using four representative inkjet printing systems designed for home, office and
archive use. Comparisons were based on two bubble inkjet
printers (printer A with an aqueous inkjet ink; printer B with
an aqueous alternative inkjet ink), a piezoelectric printer
with solvent wax ink (printer C) as well as a piezoelectric
printer with an aqueous inkjet ink (printer E). The prints
made by a colour laser printer (printer D) served as the reference for comparison purposes. A wide selection of different
papers was printed in order to cover different applications.

To simulate application-oriented conditions, the prints were

subjected to the following ageing conditions for approximately one year:
Climatised room 23C/50 % rel. humidity, in darkness
(in a closed folder),
Office (artificial light, dry),
Behind a window pane (with incident sunlight).
A testo 545 light meter with a measuring range from 0 to
100,000 Lux was used to determine the amount of radiation
the print samples were exposed to while they were being
stored in the office and behind the window pane. The colour changes in the prints were evaluated at predetermined
time intervals.
Storage in darkness
The trials simulated the type of long-term storage that is
most common both in archives and in the home, i.e. storage
of documents in folders without incident light. The trials
were intended to show the extent to which prints fade even
under such storage conditions and how properties such as
legibility or surface strength change.
The results showed that colour changes occurred in the
prints in the visually barely noticeable range (change in
chromaticity co-ordinates E to 5) irrespective of the paper
grade or printer. Even here, it became clear that findings
regarding the stability of the prints are always dependent
on the printer-paper-ink system and therefore cannot be
generalised (see Figure 1.) Under these ageing conditions,
the stability of the inkjet prints was equal to or better than
the stability of the laser prints (see Figure 1, laser printer =
printer D). It is absolutely essential to systematically select
papers that match the corresponding printer-ink system to
obtain prints that are as resistant to ageing as possible.
When the prints stored in darkness were evaluated visually
a year later, their photo quality showed no changes that
would disturb the human eye (change in chromaticity coordinates of E < 1). Even legibility, surface strength and
resistance to agents did not change at all during the year of

PTS NEWS 01/2010

2,5

black
cyan

1,6

magenta
yellow

1,4
1,2

1,5

delta E

delta E

1,8

magenta
yellow

black
cyan

Research

1
0,8
0,6
0,4

0,5

0,2
0

paper

10

11

Fig. 1: Change in chromaticity co-ordinates after one year of storage in

darkness (climatised room) printer E (inkjet)

black
cyan

12

Fig. 2: Changes in chromaticity co-ordinates in the prints made by different printers (paper 12 multipurpose copy paper) after a year of
storage in darkness (climatised room)
4,00

magenta
yellow

magenta
yellow

black
cyan

3,50
3,00

delta E

delta E

printer

4
3

2,50
2,00
1,50

1,00

1
0

0,50
A

printer
Fig. 3: Changes in chromaticity co-ordinates after a year in office storage (paper 12 multipurpose copy paper)

storage compared to the original state. Moreover, these results were totally independent of the printer or paper used.
The only exceptions were the prints that had been made on
recycling paper (papers 8 and 9) using printer E, as these
prints were found to have suffered a slight deterioration in
print contrast after a year of storage.
The results of these trials demonstrated that storage of
inkjet prints in darkness under constant climatic conditions
did not exhibit any disadvantages compared to prints produced by electrophotographic printing.
Office storage not in direct daylight
Prints frequently lie on desks or hang on wall charts for
longer periods of time in offices and are thus exposed to artificial light in a day-night rhythm. The results of these trials
demonstrated that inkjet printers achieved results compar
able to those of laser printers even under such storage conditions. The changes in chromaticity co-ordinates in most
of the printer-paper combinations were generally less than
one E of max. 5. The colours yellow and magenta showed
the greatest reaction to the office light situation.
The storage of prints in the office, however, resulted in visible colour changes in those prints that had been printed
using wax ink (printer C). All of the other prints produced
by printers A and E (except for the yellow colour of printer

0,00

paper

10

11

12

Fig. 4: Changes in chromaticity co-ordinates after a year in office storage (paper A bubble inkjet printer)

E) and the laser prints (printer D) remained significantly

less than E = 3 in most cases (see Figure 4). In the case of
the prints made by printer C (wax ink), the most significant
changes were found in the colours magenta and cyan, e.g.
on paper 3 (inkjet, standard matte) with as much as E =
8, whereas only slight changes in chromaticity co-ordinates
were observed in the case of black and yellow with a E
from 1.5 to 2. The results were highly dependent on the
paper grade used.
It is evident from Figure 4 that the ageing stability of the
prints can be optimised by selecting an appropriate grade
of paper. The trial findings revealed that prints made on
special inkjet printing paper (papers 1 to 4) did not necessarily achieve the best ageing stability. The prints made
with printer A (bubble inkjet) on multipurpose papers 6,
10 and 12 proved to have much greater light stability than
the prints made on special inkjet printing paper. Under
the storage conditions described above, inkjet prints thus
achieved virtually the same good light stability as coloured
laser prints when the printers and papers were selected appropriately.
Storage behind a window pane in direct daylight
Prints are often exposed to direct sunlight for long periods
of time behind a window pane as notices or announce-

PTS News 01/2010

60,00

black
cyan

50,00

Research

70

magenta
yellow

delta E

delta E

magenta
yellow

50

40,00
30,00
20,00

40
30
20
10

10,00
0,00

black
cyan

60

0
1

10

11

12

paper
Fig. 5: Ageing behind a window pane printer A (bubble inkjet printer)

ments, placards or posters or as documents mounted in

glass picture frames. This ageing situation was simulated in
another set of trials.
When prints were stored behind a window pane, much
higher irradiation energy including part of the daylight UV
radiation acted on the prints. The colour differences were
accordingly greater after a year of storage. Significant differences again became evident depending on the printer-inkpaper combination that was used (see Figure 5).
The colour stability of the inkjet prints was significantly
poorer in the case of yellow and magenta when compared
with the stability of the laser prints (printer D). The results obtained with the colours black and cyan, on the other
hand, were comparable to those produced by electrophotographic printing (see Figure 6).

printer

Fig. 6: Ageing behind a window pane (prints on paper 12 - multipurpose copy paper)

Conclusions
When inkjet printing technology is used to produce coloured
prints, both the fields of application and the resulting requirements and storage conditions must also be taken into
consideration. Systematic selection of the three components
of the printing system, i.e. the printer, printing ink and paper, is essential to achieve optimum ageing and light stability. PTS can provide effective support when a decision is
pending for a specific print system using the requirements
profile developed in the project for different fields of application and with the help of the test method developed for
accelerated light-induced ageing of coloured inkjet prints.

Contact
Katrin Khnl
0049 3529 551 658
katrin.kuehnoel@ptspaper.de

PTS-CTP Deinking Symposium

27th - 29th April 2010 in Munich
After many years at different venues, the PTS-CTP Deinking Symposium returns to Munich this year - it will be held at Papiertechnische
Stiftung from 27 to 29 April 2010. Lectures of the first conference
day focus on trends in deinking, recovered paper sorting and measuring methods. Day two concentrates on deinking chemicals, treatment technology, DIP quality and waste. The Symposium will be
completed by sessions on stickies, recyclability and digital printing
on the third conference day.

Registration: www.deinking-symposium.com

10

PTS NEWS 01/2010

Customer projects

Informative and practically relevant results about anaerobic

biodegradability
PTS develops improved test stand for semi-continuous investigations of anaerobic degradability, additive effects on
anaerobic degradability and sludge activity.
The anaerobic pre-treatment of effluents and partial effluent
streams is an established technology in the paper industry.
Its main advantages over aerobic methods are the low energy demand and sludge production as well as the possibility
to use the biogas produced for energy recovery.
Plant operators considering the installation of an anaerobic treatment stage must prove that their (waste) waters
are suitable for anaerobic degradation and that the planned
process is economically efficient. Effluent streams can contain varying loads of numerous ingredients many of which
have unknown effects on the biocenosis of the treatment
plant. This renders the design, dimensioning and operation of anaerobic treatment stages difficult. It is therefore
necessary to comprehensively investigate the interactions
between all effluents the plant could possibly treat and the
morphology and composition of anaerobic sludge chosen
for the treatment method. Knowledge must be gained about
the inhibitory or stimulating effects of effluent compositions
on anaerobic metabolic processes. Anaerobic sludge of existing plant systems must be tested on possible changes in
its activity when in contact with effluent streams containing
higher loads or problematic substances. Furthermore, plant
operators need a tool to investigate the causes of failures or
operational trouble in plant systems which had functioned
well so far.
These tests are frequently assigned to laboratories because
of the significantly lower costs involved. The standardized
methods available for this purpose (DIN EN ISO 11734 and
DIN 38414-S8) are based on low substrate concentrations
because they focus mainly on the fouling properties or
anaerobic degradability in digested sludge. To meet the demands of anaerobic treatment stages in the paper industry,
PTS has developed a method for anaerobic biodegradability
tests [1].
Basis of the method
Anaerobic degradation is a sequence of various complicated microbiological steps converting the organic substances
present in effluents into biomass, methane, carbon dioxide and hydrogen [2]. By monitoring the reduction of starting materials and increase in products, conclusions can be
drawn on the progress of biological degradation. A certain
amount of the substance to be tested is mixed with anaerobic sludge and kept in a closed system under pre-defined
conditions. The effluent is sampled at regular intervals, and
the biogas formed is measured. Chemical analyses of selected effluent ingredients and of the biogas formed as well
as visual assessments of the effluent/sludge system make it

Graduated
eudiometer

Storage tank
Sealing liquid
Biogas supply
for eudiometer
Filling and sample
port with dip tube

(Waste)water
Anaerobic sludge
Fig. 1. Anaerobic test design (schematic)

possible to evaluate the degradability of effluent ingredients

and sludge performance.
Since 1997, PTS scientists have been using the PTS method
WA 003/97 developed by them to evaluate the anaerobic
degradability of organic substances present in circulation
waters and (partial) effluent streams of the paper industry. Even though the PTS method deviates slightly from the
preparation conditions and procedures specified by standard methods, it has proved valuable because it is very close
to the conditions prevailing in anaerobic treatment systems
of the paper industry. The test procedure provides information about acutely inhibitory or facilitating effects of effluent composition and effluent ingredients on the anaerobic
metabolic processes of micro-organisms, and about the activity of anaerobic sludge. It is also possible to study the
inhibitory or toxic effects of chemical additives by adding
the desired additive concentration to the test preparation
(real or synthetic effluent). Degradation performance and
possible failures in anaerobic degradation can be identified
by evaluating the degradation behaviour and biogas production.
The demand for anaerobic degradation tests has changed:
Plant operators are now looking for tests capable of approximating their mill processes and of representing also
chronic effects of effluent ingredients. In tests based on the

PTS News 01/2010

Customer projects

11

STEP ONE

Start: add the effluent,

nutrient salts, trace
elements, anaerobic
sludge

STEP TWO

STEP THREE

Sampling of effluent:
take effluent samples
up to a height directly
above the sludge level

Add fresh water:

via the sample port,
fill up to the pre-defined
overall volume

Fig. 3. Sequence of semi-continuous anaerobic tests

DOCel in %

100

Fig. 2. Preparation block 1 of the anaerobic test design

80
60
40
Reference
Additive no. 6
Additive no. 13

20

PTS method, mill conditions can be approximated by semicontinuous operation whilst maintaining the basic conditions of the PTS method PTS-WA 003/97:
Test design and procedure
The schematic test design is shown in Fig. 1. The effluent
sample is mixed with anaerobic sludge (sludge load in the
preparation: BoTS = 0.2 0.5 g COD/g DM, usually 0.3 g
COD/g DM), trace elements and nutrient salts. The mixture
is treated with nitrogen to generate an oxygen-free medium.
The system is kept gas-tight during testing, maintaining predefined conditions. The progress of biodegradation, degradability of effluent ingredients and sludge performance are
monitored over time by analysing the effluent loads at regular intervals and measuring the biogas formed.
To ensure optimum degradation conditions, the temperature
of the preparations is maintained at 36C 2C by means
of a thermostatted water bath. The biogas is measured via a
eudiometer system (liquid displacement).
Two preparation blocks make it possible to simultaneously investigate several samples (Fig. 2) whilst ensuring the
comparability of sample preparations.
Gas volume produced in m/po Vo

2000
1500
1000
500
0

10

Fig. 5. Biogas production of test preparations

15

time in d

20

10

15

time in d

20

25

30

Fig. 4. DOC elimination of test preparations

The design of the bottle makes it possible to take and add

samples from and to the reaction space, enabling semi-continuous additions of real or synthetic effluents and additives, if desired. Semi-continuous additions are performed
2 3 times per week, using the sequence shown in Fig. 3.
Application example
The method has already been used for anaerobic degradation tests of various additives. Changes in anaerobic degradation properties were observed for a flocculant based on
cationic polyacryl amide (additive No. 13) and a polymer
based on cationic polymer (additive No. 6).
No significant differences were found between test preparations and a reference sample regarding DOC elimination
(Fig. 4). This indicates an apparently undisturbed anaerobic
degradation process (faulty addition of synthetic effluent
for additive No. 13 on testing days 8 12).
DOC was reduced by both degradation and abiotic elimination in this test, as shown by the
development of biogas production
for additive No. 13 (Fig. 5).
The presence of additive No. 13
reproducibly and significantly reduces the biogas volume formed
by around 5 15 % over a longer
Reference
Additive no. 6
period, which is particularly obviAdditive no. 13
ous when looking at the specific
biogas volume (Fig. 6). During
25
30
practical operation, biogas losses

Specific biogas production in m/kg DOCeli

12

PTS NEWS 01/2010

Customer projects

3,0
2,5
2,0
1,5
1,0
0,5
Reference

0,0

Additive no. 6

12

Additive no. 13

15

19

22

26

Testing day in d (fresh additions of synthetic effluent and additive)

Fig. 6. Specific biogas production of test preparations

of this magnitude would result in considerable financial

losses due to forgone energetic uses.
Besides biogas losses, the preparations with additive No. 13
showed strong and almost eruptive pellet flotation due to
gas bubbles attaching to pellets, as can be seen in Fig. 7.
Conclusions
Requiring little time and effort, the PTS method provides
meaningful, practically relevant and reproducible results
about anaerobic biodegradability also during semi-continuous operation. It is capable of detecting acute toxicity
and of predicting the chronic effects of substances present
in effluents.

Literatur
[1] NN
PTS-Methode PTS-WA 003/97
Bestimmung der anaeroben biologischen Abbaubarkeit
Papiertechnische Stiftung, Mnchen (1997)

Gas bubbles
Fig. 7. Left: test preparation with pellet flotation, right: magnified flotation layer gas bubbles attached to pellets

[2] BISCHOFSBERGER W.; DICHTL N.; ROSENWINKL K.-H.;

SEYFRIED C. F.; BHNKE B.
Anaerobtechnik
2., completely revised edition; Springer-Verlag Berlin Heidelberg 2005; ISBN 3-540-06850-3

Contact
Gabriele Weinberger
0049 89 12146463
gabriele.weinberger@ptspaper.de

PTS international Paper Symposium: 7-10 September 2010 in Munich

The PTS International Paper Symposium was facelifted
two years ago. The first day addresses in particular the
corporate management level, whereas the second and
third days then focus on technological themes in papermaking, plant engineering and measurement technology. The Paper Showcase will present interesting and
topical market developments and trends. The Hot Spot
will spotlight a theme that is currently a burning issue in
the paper world.
Based on this concept, the Symposium provides a solid,
in-depth overview of current developments in the production of paper and paperboard. The Symposium will
focus on an exchange of opinions and technical discussions between professional colleagues and experts. The
event is geared to all employees from companies that
manufacture specialty and mass-produced paper including their customers and suppliers.

Thematic focal points are:

Paper Showcase: market developments and trends
Hot Spot: a current topic in the paper industry
Intelligent resource utilisation
oo Material-saving implementation of product properties
oo Increasing the specific performance of raw materials and additives
oo Exploiting the interactions between the pulp and
additives
oo The economical use of energy and water
Efficient process management
oo Designing low-loss processes
oo Economical process control
oo Database process and quality evaluation
Excursions

www.paper-symposium.com

PTS News 01/2010

Customer projects

13

SUCCESSFUL WATER CIRCUIT OPTIMISATION

AT SAPPI MAASTRICHT AND HAMBURGER RIEGER
The European research project AquaFit4use aims at a
more sustainable use of water in the main water consuming
industries: paper, chemical, food and textile industry.

points enables a more efficient use of limited water resources: Reduction of fresh water losses, reduction of flow rate of
individual consumers and changeover to clear water supply.
Furthermore, the recirculation of biologically treated water
was simulated. This also included the integration of tertiary
treatment units like nanofiltration and ozone treatment. The
simulation results show promising starting points for a reduction in the fresh water consumption while keeping the
system loading within a tolerable range.
Based on the systematic assessment and evaluation of the
current state and the results of the simulation studies the
circuit closure potential could be evaluated and optimisation measures could be elaborated. Action plans with single
measures, partly including several alternatives, were developed within this project for a reduction of the specific fresh

Consequently, the intake of fresh water and the disposal of

waste water will be reduced significantly as will the burden
imposed by this on the environment. Sub-Project SP5 Pilot
cases in the four related target industries is coordinated by
PTS in cooperation with 27 partners from 11 European countries. SP5 is a crucial part of the EU-project AquaFit4use
integrated in the 7th Framework Programme on Research
and Technology Development of the European Commission.
The overall goal of Sub Project SP5 is to lay the basis for narrowing water circuits in the four related sectors. Sappi Limburg Maastricht Mill, Hamburger Rieger and PTS have joined
forces to meet these challenging goals.
To serve an adequately sized portion of the paper
sector the pilot studies were executed in paper
mills producing different paper grades with different requirements to water quality. Sappi Limburg
Maastricht Mill is part of the Fine Paper Europe
division in the Sappi group. Coated graphic board
is produced on one paper machine equipped with
an inline coater and an offline coater, using virgin
fibres as raw material. Hamburger Rieger located
in Trostberg is part of the Hamburger Containerboard division in the Prinzhorn Holding. Coated
and uncoated liner and board grades are produced on a 4-ply-fourdrinier machine and a 9-ply
vat machine. 100 % recovered paper is used as
raw material.
Extensive mill investigations were carried out to
establish starting points for each mill for the implementation of cost-effective water circuit opti- Fig. 1: Sappi Limburg Maastricht mill
misation measures. A systematic assessment and
evaluation of fresh water use and all relevant contraries (i.e. organic and inorganic loads) was performed. The determination of key figures helped
to identify fresh water losses and water system
optimisation potentials. This led to a comprehensive mapping of the water circuits and relevant
loadings in water streams. The mill investigations
covered the entire site, including paper machines,
coating department and waste water treatment
plant.
Tailor-made static simulation models of the water and stock systems of the involved paper mills
were created to predict the impact of different integrated water resource management approaches
on water quality and process stability. Testing of
several scenarios for a possible reduction in the
water consumption using the following starting Fig. 2: Hamburger Rieger Trostberg mill

14

water consumption and an optimisation of the water circuits.

The identified fresh water savings potential amounts to approximately 30 % of the current fresh water intake in both
mills. Some of the proposed measures have already been implemented or selected for implementation in 2010.
Future prospects: Narrowing more and more water circuits
corresponds to increasing concentration levels of detrimental
substances in process waters. However, meeting water quality requirements to ensure process stability and product
quality calls for keeping the concentration levels of these
compounds below a certain level. To ensure a possible re-use
of high-quality water, pilot trials will be performed at Hamburger Rieger within the frame of AquaFit4Use in 2011. For

PTS NEWS 01/2010

Customer projects

this purpose, innovative anaerobic and aerobic reactors will

be tested in combination with advanced separation and oxidation technologies.

Contact
Holger Jung
0049 89 12146133
holger.jung@ptspaper.de
www.aquafit4use.eu

New technologies for papermaking and pulp upgrading at the pilot

plant in Heidenau
Despite its difficult business situation, PTS has accomplished
further modernizations in its pulp and paper pilot plant in
2009, thus broadening the range of tests and trials available
to our customers and researchers. The modernizations were
made possible by the INNOKOM East programme of the German Federal Ministry of Economics and Technology (BMWi),
which provided 90% of the funding.
Initial situation
The pilot plant of PTS Heidenau has made a name for itself
across Europe in the fields of industrial collective research,
contract research and training. Since 2007, its stock preparation, pulp upgrading and papermaking facilities have
been frequently booked for multi-client projects (cf. several
detailed reports in previous issues of PTS News). However,
the project work also showed that the pilot plant facilities
were in need of modernization to meet future requirements.
More specifically, preconditions had to be created for:
fibre-additive and fibre-filler compounds, and
operating the pilot paper machine in a closed circuit by
using its white water for stock dilution.
In 2009, PTS therefore applied to the Federal Ministry of
Economics and Technology (BMWi) for funding of the following investment projects:
disperger and homogenizer test stand for compounds
and fillers, and
circuit closure of the pilot paper machine.
Special care was taken to ensure that the various test stand
components are flexibly applicable. By now, PTS has already gained initial operating experience with the new test
stands.
Disperger and homogenizer test stand for compounds
and fillers
Core piece of the test stand is a fully enclosed rotor-stator

Fig. 1: Rotor and stator of the disperger system

machine from the company Cavitron. Its tool geometry and

process parameters can be adjusted to realize two modes of
operation: disperging to produce a homogeneous mixture of
the components without comminuting or destroying the primary structures, and homogenization / comminution of so
lids by applying extremely high shear and cavitational forces.
The special design permits peripheral speeds in excess of 50
m/s, which increases the power input significantly. With
its maximum throughput of 2 m/h (related to water) and
direct additive dosing, the equipment fills the gap between
laboratory and full-scale systems, making it possible to draw
conclusions about basic plant and process parameters of fullscale systems. Moreover, the system is capable of producing
adequate amounts of sample material for subsequent pilotscale processes.
Initial developments involving this type of equipment have
already been developed in R&D and customer projects on
thermo-mechanical starch digestion in recent years. In future the system will increasingly be used in the field of stock
preparation to develop fibre-filler compounds and finely
structured celluloses.

PTS News 01/2010

Customer projects

15

Grammage in g/m / Ash content in %

Zeta potential in mV

Circuit closure of the pilot paper

Process
Paper machine
chemicals,
machine
fillers
Technological realization
Static
mixer
The following units were added to the
existing pilot stock preparation sysIDM
IDM
tem (Fig. 2):
Thick stock chest
Machine
Stock pump
chest
adjustable thick stock pump
Paper
Process
chemicals,
adjustable pump for white water
fillers
from the pilot paper machine
inductive flowmeters for partial
White water
streams
IDM
250 l white water chest with level
IDM
indicator
White water tank
White water pump
150 l machine chest with level indicator
Fig. 2: Pilot paper machine circuit closure
4 vessels (capacity of 400 l)
with adjustable agitators (can be
60
55
55
55
54
54
53
53
switched on automatically at regu
50
50
50
50
47
47
47
45
45
44
43
lar intervals) for the long-term
41 40
40
storage of filler suspensions and/
30
26
or process chemicals
20
2 vessels (capacity of 40 l) with ad10
9
justable agitators for adding filler
0
suspensions and/or process chem-3
0
30
60
90
120
150
180
icals in the paper machine
-10-11
All pumps are controlled manually
-20
Zeta potential MC
Zeta potential headbox
to adjust a previously calculated set
-30-31
point. We intentionally abstained
-40
from using automatic control systems
Time in min
here for cost reasons and because we
Fig. 3: Circuit closure Zeta potential as a function of trial time
have learned from experience that
trial processes involving frequently
80
changing stock models can be bal75
75
75
75
74
74
74
74
74
74
73
anced much faster by manual control
71
70
performed by highly skilled opera65 64
tors.
60
55

Initial operating experience

50
The new system had to be tested to
46
46
46
46
46
46
45
45
44
44
determine the time it takes to reach
44 43
40
the equilibrium. For this purpose, we
38
Grammage, conditioned
Ash 900 C
35
choose a stock model comprised of
30
pulp/filler/wet strength resin and pH
0
30
60
90
120
150
180
adjustment at the headbox. A typiTime in min
cal characteristic of this model is the
Fig. 4: Circuit closure grammage and ash as a function of trial time
strong effects of zeta potential at the
headbox on filler retention and grammage. In a three-hour trial, the dosing
test parameter settings in a closed circuit, it will therefore
parameters of the system were kept constant and samples
be necessary to allow for trial times between 45 and 60 min,
were taken and analysed at certain intervals. The white
depending on the samples required.
water chest had to be supplied with 150 l fresh water during start-up.
Possible uses for R&D projects and customer trials
Figures 3 and 4 show selected results of the trials (zeta po Simulation of near-practical pilot paper machine operatential, grammage and ash). Despite its small dead volume,
tion by using its white water,
the pilot system took 30 minutes to reach equilibrium. To
improved optical homogeneity of sheet structures, espe-

16

cially in the case of highly filled papers, by increased

fines and filler concentrations in the white water circuit,
reduced water consumption when producing small
batches and application samples, and
possibility of continuous additive dosing to thick stock
with selected residence times.
Acknowledgement
The project was funded by the German Federal Ministry of
Economics and Technology (BMWi) under the programme
R&D promotion for non-profit external industrial research
institutions in East Germany innovation competence east
(INNO-KOM-Ost) in the 2009 model project Investment
grants for technical infrastructure. We would like to express our sincere gratitude for this support. We would also
like to thank the companies of the paper and supply sectors
for bearing part of the costs not covered by the Ministry.

PTS NEWS 01/2010

Customer projects

Contacts
Dr. Herbert Berger
Head of pilot plant
0049 3529 551 660
herbert.berger@ptspaper.de

Steffen Schramm
Trial manager
0049 3529 551 679
steffen.schramm@ptspaper.de

Tiemo Arndt
Head of Department Fibre Technology
0049 3529 551 643
tiemo.arndt@ptspaper.de

Using PTS models for web-based simulation and optimisation

PTS is expanding its portfolio of services by offering the PTSProductOptimizer via the Internet. This gives PTS customers
and partners the opportunity to use their specific models
even after the respective project has expired.

simulation tools from the PTS-ProductOptimizer product line

(see News 01/02 2009) in a large number of research and
customer projects in which PTS has created customer-specific models.

Initial users already have online access to their models

which allows them to directly utilise the know-how that
PTS has gathered in long years of development work. With
the help of simulation, physical and data-based models can
assist you in taking decisions regarding
formulation changes evaluate and optimise product
properties and costs
evaluation of process alternatives (e.g. prior to rebuilds)
optimisation of water circuits
and many other aspects.

Tailor-made models
The models are configured for plant-specific requirements
and thus yield results that are both consistent for the facility and tailored to the individual user. The model and user
interface are adapted in each and every case.
Users can thus utilise PTS simulation tools and databases in
a fast, comfortable and cost-effective manner. The tools and
databases can be reached via an Internet access and a Web
browser. No other additional software is required.
A high level of security for users is guaranteed by a user authentification via the Apache HTTP Server and by the controlled access to compute servers on which the user-specific
simulation models and databases are safely embedded and
securely protected.

What are the advantages?

Simulation tools give you total control over process complexity. Virtual trials are a quick and cost-effective way
of checking out different options for action even beyond
the testing conditions that can be examined in mill trials. The impact of
intended measures can be quantified
even before the trial begins. Optimisation functions that have been integrated in the tools make searching for
optimum production conditions easy.
PTS has been successfully using such

PTS - Heidenau location

User authentification
Models,
Databases

Parameters, results

Web server

Compute server

PTS News 01/2010

Customer projects

How a web-based simulation works

1. The user logs onto the web server (authentification)
2. The web server provides the user with the user interface
(parameter sets and model databases are loaded from
the users database)
3. The user enters the simulation parameters (e.g. parameters for stock preparation and paper machines)
4. The user starts the simulation (the simulation can be

17

manually restarted several times during one session with

varied parameters)
5. The simulation proceeds automatically on the PTS compute server
6. The results are displayed on the user interface (e.g. product properties and costs)
PTS will provide information updates as this range of ser
vices is expanded.

Test model now available online!

A simulation model is now available for testing purposes. It
is a general model designed to Forecast the process water
load in a paper mill loop for linerboard grades. Anyone
interested in using this model can familiarise themselves
with the representative functionality and normal handling
of a simulation tool.
The model depicts the water circuit and effluent treatment
plant of a typical paper mill that produces linerboard. It
models a system comprising a stock preparation plant and
one paper machine loop. The effluent treatment plant is
designed as a combined aerobic-anaerobic plant.
It is possible to forecast in advance COD values and calcium
concentrations at the paper machine and in the effluents on
the PC with the aid of the simulation tool. During this process, the user can test the impact that the following options
for action may have:
Closure of water circuits as a result of fresh water savings
Water loop separation by installing a thickener for the
finished stock
Countercurrent layout by using fresh water in the paper
machine and discharging effluents from the stock preparation plant
Recirculation of biologically treated water by integrating
a biological treatment stage
Dissolution of calcium carbonate
The parameters are entered into the simulation model and
the results of simulation are displayed conveniently via the
web portal user interface refer to the image.
And you will find the test model on our homepage here:
http://shpoint.ptspaper.de:8080/CSB-WPR
Of course, this simplified model cannot provide answers to
all questions relating to your water circuit. If you are interested in using this service to model your water circuit,
please do not hesitate to contact us.

Contacts
Achim Hutter
Water circuits
0049 89 12146 227
achim.hutter@ptspaper.de

Sven Altmann
Online application
0049 3529 551 634
sven.altmann@ptspaper.de

18

PTS NEWS 01/2010

Customer projects / Testing

PTS soft sensor Virtual fractionation now available

as demo version
The PTS-SoftMcNett sensor developed
by PTS calculates fibre fractions automatically using the data from imageanalytical fibre measurements. It is
being used successfully for the quality
control of TMP at Norske Skog (see
PTS News 02/2009) and in various
customer projects.
The software uses analytical discrim
inant functions to calculate the fractionation effect of McNett classifiers,
taking into account the length, diameter and wall thickness of fibres.
Its main advantage is the fast, highly
accurate and reproducible calculation
of fibre fractions. Costly and timeconsuming manual fractionation tests
in the laboratory have thus become a
thing of the past.
The PTS-SoftMcNett is now available
as a demo version for free trial on
the PTS homepage. Using virgin pulps (refined/unrefined)
and recycled fibre pulps as examples, the demo version
shows quickly and conveniently how efficient the virtual
fractionation is. The mass shares of calculated McNett fractions and ash contents of recycled fibre pulps are shown in
diagrams.
If interested, we can send you a full version free of charge
for a limited evaluation period.

Contact
Sven Altmann
0049 3529 551 634
sven.altmann@ptspaper.de

New IR spectrometer broadens range of paper and raw material

analyses offered by PTS
With its new FT IR spectrometer, PTS is able to make important contributions to the identification and quality control
of paper, raw materials and composites. The new measuring system will be used for PTS research, service and consultancy projects.
Infrared spectroscopy is a type of spectroscopy based on
molecular vibrations which is particularly suitable for nondestructive identification of organic compounds. Functional
groups have characteristic vibrations corresponding to certain absorption bands in the IR spectrum. Because functional groups absorb radiation in a characteristic range, an
unknown substance can be readily assigned to a substance
class (aromatic compounds, alcohols, ketones, amines etc.).
By comparing the measured with reference spectra (in a database, for example), it is even possible to accurately iden-

Testing

tify a chemical structure or substance.

The spectrometer from the company Bruker available at PTS
Heidenau measures in the medium infrared range (wavelengths between 4000 and 400 cm-1). It is comprised of a
Tensor 27 ATR spectrometer and Hyperion 2000 microscope
system and can be operated in the measuring modes transmission, reflection and ATR (attenuated total reflection).
The microscope system permits measurements of details
having a minimum diameter of approx. 20 m. The motordriven x-y table provides for the scanning of entire areas
to determine the distribution of chemical substances, for
example. The diagram shows the FT IR spectra of two papers.
Analyses can be performed with very small amounts of sample material be it paper or raw materials. Powders, films
and papers can usually be measured directly in the ATR
or reflection modes, i.e. require no further sample preparation, but it is also possible to produce tablets or extracts for
measurements in the transmission mode.
Among other, the IR spectrometer is used for the following
tests:
comparison of batches to identify product differences
identification of impurities, defects and inhomogeneities,
for example in the case of delamination defects
failure analyses
composition analyses of unknown materials (competition analyses, for example)
(semi)quantitative tests
changes in chemical structure over time (ageing, chemical reactions, etc.)

19

1,2

Transmittance [%]

PTS News 01/2010

1
0,8
0,6
0,4
paper 1

0,2

paper 2

0
3650

3150

2650

2150

1650

1150

650

wave number [1/cm]

FT IR spectra of two papers

The measuring system was procured under the 2009 model

project Investment grants for technical infrastructure in
the programme R&D promotion for non-profit external industrial research institutions in East Germany innovation
competence east (INNO-KOM-Ost).

Contact
Nicole Brandt
0049 3529 551 670
nicole.brandt@ptspaper.de

New paper-analytical methods based on Raman spectroscopy

About ten years ago, improvements in the measuring technology of Raman spectroscopy led to its development from a
purely scientific method into a routine laboratory procedure.
Raman spectroscopy has significant advantages over other
spectroscopic measurements and is particularly suitable for
chemical analysis of paper requiring high local resolution
levels. PTS has joined forces with researchers at Dresden
Technical University to make this relatively new technology
available and usable for routine paper analysis.
The cross-sectional distribution of substances (distribution
in z-direction) has a key influence on many use and converting properties of paper, for example strength characteristics or printability. It is therefore important to know the
z-distribution of paper components. However, analytical
methods investigating the structure and composition of paper in z-direction have been lagging behind surface-analy
tical methods (x-y direction) to this day. Measurements in
z-direction continue to present a major challenge regarding
both local resolution and material specificity.

Raman spectroscopy
Raman spectroscopy offers new opportunities to analyse
the z-distribution of substances in paper, making it possible to selectively detect organic and inorganic chemical
compounds. It is a spectroscopic measuring method used
to study molecular structures. The Raman bands of a spectrum can be assigned to certain groups of molecules and,
thus, chemical compounds. The band intensities or ratios
between them give quantitative information.
The use of an excitation laser and an optical microscope
provides for a very high local resolution of up to 1 m. Paper samples can be measured directly, i.e. there is no need
for lengthy or complicated preparation procedures. To study
the distribution of substances, spectra are acquired point by
point across the entire cross-section of the paper. The data
collected in the scanned area (mapping file) can then be
used to generate spectral images.
Spectral images can be generated in different ways, i.e.
there are several options for the colour-coding of measuring
points:

20

PTS NEWS 01/2010

Testing

intensity of a characteristic vibration band

intensity or area ratios between
two bands, for example of the paper matrix and the substance to be
detected
classification of spectra by chemometric techniques, for example
principal component analysis or
cluster analysis
The values determined for colour
coding can also be used to obtain relative and absolute distribution curves
across the paper cross-section.
Paper-analytical applications
Figure 1 illustrates a measurement Fig. 1: Video image of a photo inkjet paper cross-section (left). Spectral image of the cross-section
showing five layers (top right). Raman spectra of individual layers (bottom left).
across the paper cross-section. The
video image shows the cross-section
of a photo inkjet paper together with the grid of measuring
one of the main aims of the Raman studies done by PTS. A
points (step size 2 m). Next to it is the coloured Raman
first practical solution, using the starch distribution across
spectroscopic image. The score values of the second princithe paper cross-section by way of example, is the subject
pal component determined by principal component analyof a diploma thesis being written by a TU Dresden student
sis were used for colour coding. All paper layers could be
under the supervision of PTS.
resolved - the Raman spectra of individual layers are shown
Raman spectroscopy is particularly suitable for starch analbelow the spectral image.
ysis because the numerous OH groups present in starch
What is remarkable about this result is that the optically aland also cellulose give no signals in the Raman spectra.
most indiscernible base ply of the ink receiving layer (layer
Therefore, unlike infrared and near infrared spectra, the RaB) could be made visible by the Raman measurement. The
man spectrum shows many other typical vibration bands of
visualisation of optically indiscernible paper components is
starch which can then be evaluated. Moreover, the signals

Fig. 2: Raman spectra of cationically modified starches having different degrees of cationization (DS). The characteristic bands of cationic substituents are marked (from E. Pigorsch, Spectroscopic Characterisation of Cationic Quarternary Ammonium Starches, Starch/Strke 61 (2009)
pp.129-138)

PTS News 01/2010

Testing

generated by substituents can be easily identified in cationically modified starches (Figure 2).
Further possible applications of Raman spectroscopy for
cross-sectional analyses of paper are studies into:
coating binder distribution
resin migration in decor paper
ink penetration depth
layer compositions of paper and coatings
Further PTS research will be dedicated to studying practically relevant paper systems by means of Raman spectroscopy to demonstrate the applicability and efficiency of the
method for analysing typical paper components and their
concentrations in the paper. Initial results of this work will
be presented at the new PTS seminar Modern analytical

21

methods in papermaking at PTS Heidenau on 26 and 27

October 2010. Detailed information about the seminar is
available on the PTS homepage at www.ptspaper.de (Training).

Contact
Dr. Enrico Pigorsch
0049 3529 551 678
enrico.pigorsch@ptspaper.de

First round robin test of DOMAS Version 3.0 and

DOMAS ScannerAdvanced
As reported in the previous issue of PTS News, the new DOMAS Version 3.0 was launched in December 2009. DOMAS
is now offering a new feature: colour calibration based on
IT8.

Total speck areahe in mm/m

poor

900
800
700
600

Confidence interval of
DOMAS measurement
(10% + 10 mm/m)

500
400
300
200
100
0

good

Abb 1: Benchmarks for evaluating deinkability-dirt speck area

80%

Variation coefficient

To test the performance of the new system, PTS joined

forces with INGEDE to run a round robin test on dirt speck
measurements. An important question to be answered by
the test was whether the new DOMAS version can provide a
reliable basis for scanner-based INGEDE methods 2 and 4.
A set of 64 different dirt speck samples was prepared for the
tests. 12 of the samples had already been tested in a roundrobin test of the DOMAS Version 2.4 in 2008. The present
round robin test included nine new installations of the DOMAS system already being used by several paper producers, PTS in Munich and Heidenau and the Chair of Paper
Technology and Mechanical Process Engineering (PMV) in
Darmstadt or close to being delivered to paper mills.
Evaluation criterion was the requirements to dirt speck
measurements for deinkability assessment. The confidence
interval achievable by the measuring method and equipment used is 10% + 10mm/m for dirt speck area measurements. Figure 1 shows that the measuring task demanded this accuracy.
To compare the measurements of different DOMAS systems,
the variation of measuring results across all scanners is
shown for each sample in Figure 2. Each data point represents the result of one sample.
The majority of variation coefficients are within the required
interval. A closer look at the data points lying outside the
interval reveals that there was exactly one measurement in
each case where a large dirt speck located at the edge of
the sample had been assessed differently from the other
measurements. This illustrates how important it is to select

1000

70%

VarK (X) =

standard deviation (X)

means value (X)

100

1000

60%
50%
40%
30%
20%
10%
0%

10

10000

100000

Total speck area per sample [mm/m]

Abb 2: Variation between total speck area

a suitable observation window or sample position on the

scanner.
The measurements taken by the partners have shown that
the new system lives up to all expectations. DOMAS 3.0 provides an unprecedented quality and enables comparisons
between the systems of different paper mills. All DOMAS

22

PTS NEWS 01/2010

Testing

systems were operated with identical

100%
parameter settings in the test. These
80%
settings will be included in the re60%
vised version of INGEDE method 2.
Lets take a brief look at the results
40%
of the round robin test done in 2008
20%
for comparison: Figure 3 shows the
0%
results obtained by DOMAS 2.4 and a
calibrated UMAX 1120 scanner, which
-20%
P1
P2
P3
P4
P5
P6
P7
P8
P9
P10 P11 P12
was state of the art back then. The
-40%
green areas represent the expected
-60%
confidence intervals.
As can be seen in the diagram, devia-80%
tions from the mean value in the range
T1 T5 T6 T7a T8 E1 E2 E3 E4 E5 E6 E7 E8 E9
-100%
of 40-60% were quite possible here.
Abb. 3. Variation between scanners - measurement of 12 samples. Round robin test in
This was corrected by scanner-specific
2008 - old calibration method with scanners T1, T5, T6, T7a, T8
modifications of the threshold file. Old100%
er uncalibrated systems showed even
greater deviations and were therefore
80%
not taken into account here.
60%
Measurements of the same samples using the new DOMAS version 3.0 gave
40%
clearly better results. Figure 4 shows
20%
that the deviations of scanners from
0%
the mean value of all measurements
are almost completely within the inter-20%
P1
P2
P3
P4
P5
P6
P7
P8
P9
P10
P11
P12
val of (10%+10mm/m).
-40%
One reason for this is the technical
-60%
improvement in Epson V750 scanners,
which are now equipped with an in-80%
ternal white standard offering excelT1 T5 T6 T7a T8 E1 E2 E3 E4 E5 E6 E7 E8 E9
-100%
lent uniformity. Another reason is the
Abb. 4. Variation between scanners - measurement of 12 samples. Round robin test in
IT8 colour calibration of scanners de2010 - new calibration method with scanners E1 ... E9
veloped by PTS, which corrects all images prior to their specific analyses in
DOMAS. This enables the use of uniform threshold values,
Mechanical Process Engineering Chair (PMV) of Darmstadt
which will become part of the revised versions of INGEDE
Technical University for actively supporting the round robin
methods 2 and 4 as well.
test.

Based on these technical improvements PTS is now able

to offer annual calibration services for its DOMAS system.
Contact
Lamps or scanners can be replaced without problem because the system can re-calibrated to restore the previous
Jrg Hempel
parameter settings.
0049 3529 551 659
PTS considers the inclusion of DOMAS 3.0 in the INGEDE
0049 172 8695 459
methods 2 and 4 an important step towards the standardi joerg.hempel@ptspaper.de
zation of dirt speck and stickies measurements. In this context, we would like to express our sincere thanks to INGEDE
and its members as well as to the Paper Technology and

PTS News 01/2010

Testing

23

Fast and efficient quality testing of Braille on pharmaceutical

packaging now via the Internet
Quality testing of Braille on packaging is a new service offered by PTS to
respond to the increasing demand of
folding carton and pharmaceutical
manufacturers.
PTS offers the testing of tools and production samples of Braille embossing
or prints by means of its Braille Tester,
using originals supplied by the customer as reference. The Braille tester
developed by PTS measures both the
position and height of Braille dots in
accordance with the technical guidelines of the German carton makers
association FFI. The device is calibrated at regular intervals. Customers
receive a test certificate for their test
order, all test results and samples will
be archived.
To make sure that each test order is executed quickly, efficiently and at low cost, PTS uses a concept we are planning to apply also to other services in future. Relevant information, original data and test results are exchanged via
an Internet platform - only the samples themselves must be
submitted by postal mail. Tests of pre-defined sample sizes
can be conducted at a fixed price.
Customers are required to register to access the login area
of the Internet platform. This can be done in the following
way:
The customer sends a registration request by e-mail to
Braille@ptspaper.de, stating the name and e-mail address
of the contact person as well as the company name.
PTS opens a password protected login area for the customer, and sends the customer the password.
Once registered, customers can directly access their reserved
order platforms any time they like (Figure above).
Orders are handled in the following way:
Customers send their samples to PTS by postal mail.
They transfer the corresponding PDF files to their password-protected customer login area on the Internet platform.
Orders are placed by clicking the respective button,
which automatically sends an e-mail to PTS to inform us
about the order.
Samples will be measured within two working days upon
being received by PTS.
PTS posts the test certificate in the login area of the customer, notifying the customer of this by an e-mail.
After two working days at the most, measuring data and
test certificate are available to the customer for downloading.

Information about the order status can be viewed on the

platform any time.
In addition to carton measurements, PTS is now also able
to accurately measure the dies (Figure 2) used for Braille
embossing. After suitable preparation, it is also possible to
have embossed subjects other than Braille measured and
tested on packages.
The new service for carton manufacturers is another element enlarging the service range PTS is offering to paper
converters. To register for the service, just send an e-mail to
Braille@PTSpaper.de.

Contact
Jrg Hempel
0049 3529 551 659
0049 172 8695 459
joerg.hempel@ptspaper.de

information and registration:

www.paper-symposium.com

www.ptspaper.de
Papiertechnische Stiftung
Hess-Strasse 134 DE-80797 Munich Phone +49 (0)89-12146-0 Fax +49 (0)89-12146-36
Pirnaer Strasse 37 DE-01809 Heidenau Phone +49 (0)3529-551-60 Fax +49 (0)3529-551-899