JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - 54

intermediate products

In the case of the Algro Sol paper, the
coated mat finish offers a controlled surface to anchor the silicon. It is compatible
with solvent-free (thermal, EBC, UV),
solvent-based and water-based silicon systems and ensures high ply bond strength
and uniform calliper. This helps deliver
numerous properties that are important to
support the end man ufacturing process,
including superb lay flat properties,
high bulk and stiffness, high mechanical
strength, good manual handling during
processing, low hygro expansion, low
shrinkage during processing and inertness, which means there is no chemical interaction with the applied coatings. These
guarantee safer, faster and easier handling
of the prepreg material.
For many prepreg applications like the
manufacturing of sporting goods such as
skis and tennis rackets, manual handling
of the materials is part of the manufacturing process. This manual handling of the
prepreg material can be stressful if the
siliconised paper is not robust enough.
The Algro Sol series paper has a very high
dimensional stability making it ideal for
these purposes, which results from the use
of a special fibre mix and a unique drying
process when the paper is manufactured.
The unique properties of this paper, available from 80 gsm to 137 gsm, also make
it ideal for graphical pressure-sensitive
applications such as plotter (CAD/
CAM), screen, offset and digital printing.
Another benefit is the possibility to use it
in regions where climatic conditions are a
key consideration, such as high humidity
and warm temperatures.

High investment in
Alfeld Mill supports growth
Sappi has a long-term commitment to
support growth in niche speciality paper
markets such as process paper release liners for prepregs. The company continues
to make significant investments in these
areas, both in research and development
and in manufacturing capabilities.
To this end, its recent investment in the
rebuilding of Paper Machine 2 (PM2) at
the Alfeld Mill in Germany resulted in
increased production capacity for Algro

Sol and other speciality papers. The Alfeld
Mill was founded in 1706 and became
part of Sappi in 1992. The mill is equipped
with five papermaking machines, along
with an integrated pulp plant that uses
locally harvested wood. The mill holds the
OHSAS 18001, ISO 14001, EMAS and
ISO 9001 certificates and produces totally
chlorine-free (TCF) bleached chemical
pulp for its own use. Its current combined
capacity of coated wood-free, coated and
uncoated speciality papers is 300,000 tpa.
The mill has about 850 employees across
nearly 400,000 square metres of manufacturing space.
The €61 million PM2 rebuild resulted
in an increase in speciality packaging
paper production. The yearly production
capacity of PM2 for one-side coated and
MGBK (machine-glazed bleached kraft)
speciality grades will be 135,000 metric
tons. Eventually, 100% of the Alfeld Mill's
production will be comprised of speciality
papers.

Smooth cylinder improves
production and paper quality
Central to the multi-million investment
was the installation of a 135-ton MG
cylinder 6.5 meters in diameter. The MG
cylinder improves production quality,
providing a very smooth top-side surface,
high dimensional stability, higher bulk
and lower penetration of coating colour.
So with Algro Sol, for example, the special
coating and special fibre selection is dried
by the MG cylinder during the manufacturing process, which fixes the surface so
that the grade does not expand during
prepreg handling. This ensures a reliable,
high-performance grade that holds up
well with manual handling.
The rebuilt PM2 also features a new headbox with a dilution system, a pre-dryer
section as a single-tier arrangement and a
high-temperature hood. Sappi re-used the
hard nip calender and after-dryer section,
while the existing film press was fitted
with new drying equipment.
These developments underscore the
company's continued commitment to
supporting customers with a wide range

jec composites magazine / No104 April - May 2016

Focus
Sappi Fine Paper Europe (SFPE) is the
leading European producer of coated fine
paper used in premium magazines, catalogues, books and high-end print advertising.
Headquartered in Brussels, Belgium, Sappi
Fine Paper Europe is recognised for innovation and quality. Its graphic paper brands
are used for speciality labelling, topliner,
packaging papers and boards. The papers
are produced in mills accredited with the
ISO 9001 and ISO 14001 certifications
and EMAS registration for all the mills in
the EU. SFPE's mills hold chain-of-custody
certification under the Forest Stewardship
Council® (FSC®) and/or the Programme for
the Endorsement of Forest Certification®
(PEFC®) schemes.
Sappi Fine Paper Europe is a division of
Sappi Limited (JSE), a global company
headquartered in Johannesburg, South
Africa, with over 14,000 employees and
manufacturing operations on three continents in seven countries, sales offices in
50 countries, and customers in over 100
countries around the world.

of innovative grades that address key
market challenges, such as the work it is
conducting relative to prepregs. Sappi
combines a rich papermaking history
with market experience and knowledge
to develop numerous speciality grades
whose production volumes have occasionally been constrained by paper machine
capacities.
The investment in PM2 was made to
overcome these constraints by delivering a brand-new high-speed production
line that can be used to manufacture a
broad, high-quality substrate portfolio
that effectively meets just-in-time delivery
expectations and ensures that customers
receive the quality, performance, choice
and service they expect. It also allows
for increases in production of the most
suitable and best performing grades as and
when demand dictates, ensuring customer
requirements are met as expediently and
effectively as possible. n
More information:
www.sappi.com

http://www.sappi.com

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016