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ADHESIVE CONTAMINANTS (STICKIES) AND METHODS FOR REMOVAL

JOHN H. KLUNGNESS* AND MAHENDHA R. DOSHI**

*USDA Forest Service, Forest Products Laboratory, Madison, WI 53705
**D~shi & Associates Inc.. Marathon Engineers/Architects/Planners, Inc.
Appleton, WI

ABSTRACT

A variety of adhesive contaminants (“stickies”) are encountered in

wastepapers. They are broadly classified as hot melts, pressure-sensitive
adhesives, and lattices. Their properties and control methods are discussed.
Specifically, control methods include furnish selection, improved pulping end
deflaking. well-designed screening end cleaning systems, and dispersion end
additives to detackify or stabilize stickies, or both. A new technology is
also discussed regarding it’s possible application for controlling stickie
contaminants. Test methods for measuring stickies are also reviewed.

INTRODUCTION

Large amounts of wastepaper are generated every day in the United States
and interest in its reuse has increased steadily due to environmental concerns
and improved economics. In 1990, for example, 28.9 million tons of wastepaper
were collected for recycling. By 1995, that amount is expected to increase to
almost 40 million tons with a collection rate of almost 40% [1]. To facilitate
the use of secondary fibers, sticky contaminants, or "stickies,” must be
controlled [2].

CLASSIFICATION AND PROPERTIES OF STICKIES

Wastepaper bales usually contain extraneous materials such as sand,

glass, staples, nails, inks, coatings, plastic, styrofoam, wax, EVA (ethylene
vinyl acetate), SBR (styrene butadiene rubber), etc. A particularly
troublesome contaminant in wastepaper is “stickies” which, in their original
state, were used as paper adhesives. Inks end coatings can also be a source of
stickies. Four primary components of inks include pigment, vehicle, binder,
and modifier. Coating formulations contain several ingredients which can be
classified as pigments, binders, and additives, such as plasticizers,
thickeners, dispersants, dyes, preservatives, and defoamers. Note that both
inks and coatings mixtures contain binders which contribute to the stickies
problem. Common binders used in inks are hydrocarbon resins and rosin esters
while those used in coating formulations include starch, soya protein,
acrylics, end polyvinyl acetate [3,4]. An overview of Stickies was presented
by Morelend and Scott [5,6].

Mat. Res. Soc. Symp. Proc. Vol. 266. © 1992 Materials Research Society
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Stickies can generally be classified into three categories: hot melts,

pressure-sensitive adhesives, and lattices. Although wax can be a contaminant,
it is not included separately as it is similar to and an important ingredient
of most hot melts. Contaminants such es plastics and styrofoam are also
excluded from this discussion since they are not stickies.

Hot Melts

Hot melts are used in many applications such as book bindings and case
sealing end as a moisture barrier. Many boxboards are coated with hot melts
to prevent the transport of moisture. They are applied at high temperature and
form bonds upon cooling. Three primary components of hot melts are vinyl
acetate polymers end copolymers, tackifiers, and wax. The tackifier improves
the nettability of the hot melt while wax is used as a bulking agent end to
adjust the melting point of the hot melt. Tackifiera used in adhesives are
summarized in Table 1 [7].
At room temperature, hot-melt adhesives are solid. They soften at 150°
to 250° F, depending on the amount of waxes and other ingredients. Most hot
melts are insoluble in water, acidic or alkaline solutions but dissolve
readily in many organic solvents such as dichloromethane and toluene. The
density of hot melts ranges between 0.9 end 1.0 g/cc.

Pressure-Sensitive Adhesives

Pressure-sensitive adhesives (PSA’S) are primarily usedw on labels, tapes,

and self-sealing envelopes. An example is “Post-it Notes which have become
popular due to their convenience and ease of application.
An important component of PSA is a rubber elastomer such as the widely
used styrene butadiene rubber or styrene-isoprene-styrene block copolymer. A
tackifier is added to improve wettability of the adhesive to the substrate end
inorganic oxides are added as fillers.
Like hot melts, most PSA’S are insoluble in water, mild acids, end
alkalies. However, they dissolve readily in many organic solvents. Their
density can range from O.9 to 1.1 g/cc.

Lattices

Lattices are widely used in foil lamination, heat-seal, and coating

applications. They are also used on labels for varnished surfaces.
Like PSA’S, lattices contain a rubbery component (a natural or synthetic
rubber latex), and a tackifier. They are in the form of a colloidal
suspension with appropriate additives used to prevent agglomeration.
One peculiar property of lattices is that they become sticky at higher
temperature (above approximately 200° F). Otherwise, their Properties -
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similar to those of PSA’S. They are insoluble in aqueous media but dissolve
readily in organic solvents.

PROBLEMS DUE TO STICKIES

When stickies are present in unacceptable amounts, they can cause

problems with both paper machine operation end product quality. They deposit
on wires, felts, press rolls, and drying cylinders. They prevent good
fiber-to-fiber bonding end increase the risk of web breaks on the paper
machine, particularly with newsprint end tissue grades [8, 9]. Wax or hot
melts can form a thin film on linerboards, giving them a slippery surface.
Consequently, when the linerboard is wound, a telescoping roll results.
The appearance of a product can be greatly influenced by the presence of
stickies. Hot melts end wax present in the middle layer of a multi-ply
boxboard can migrate to the top end bottom surface when the board is dried.
After the board is wound, adjacent layers adhere to each other. The roll is
then shipped to a customer who discovers a hole or defect in the board.
Stickies also cause problems in high-speed printing end converting operations.

CONTROL OF STICKIES

There are five approaches used to combat stickies. They include furnish
selection, improved pulping and deflaking operations, screening and cleaning,
dispersion, and additives. Some of these have been discussed by McKinney [10]
and Doshi [11].

Furnish Selection

One of the easiest ways to avoid stickies problems is to prevent their

entry into the mill. It is very important that criteria [12,13,14] be
established for acceptable end unacceptable wastepaper. This information
should, in turn, be communicated to wastepaper dealers to maintain the quality
of incoming paper. Depending on the nature of the furnish, final product end
specific problems or customer needs, it may be desirable to measure the
concentration of stickies, plastics or clay, the brightness, freeness,
groundwood content or fiber length distribution. One or more of these
indicators of wastepaper quality may be used, depending on a mill’s particular
circumstances.

Improved Pulping and Deflaking

Once the wastepaper is accepted, it goes to the pulper where, through

proper operating conditions and accessory equipment, it is fiberized without
significant disintegration of contaminants. Important parameters include
stock consistency, temperature, low vs. high pulping intensity, end
configuration of the pulper.
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Most modern pulpers are equipped with auxiliary equipment to remove

contaminants before they are broken down into small pieces. The auxiliary
equipment includes a ragger to remove wire end string, a junker for large
contaminants, and a secondary pulper. A stream is bled off at the secondary
pulper and is subjected to mild fiberizing. High-density contaminants
accumulate in a chamber with a double-valve arrangement while stock is sent
back to the pulper or is screened in a rotary screen. Many older pulpers are
being retrofitted with these accessories while most newer pulpers come
equipped with secondary pulpers [15].
Another pulper which is gaining in popularity, particularly for newsprint
deinking, is the drum pulper [16.17,18]. Due to the absence of a high-speed
rotor, the drum pulper does not have any cutting action. As a result, many
contaminants, like plastics and book bindings, remain virtually intact end are
rejected by the associated rotary screen.
Recently, steam explosion pulping has been proposed for defibering
wastepapers [19.20]. In this pulper, loose wastepapers are subjected to steam
at about 400 psi end 400° F. When the pressure is released, the materiel
explodes and defibers. Contaminants, stickies, end inks are also dispersed in
this pulper. Long term performance of the pulp on the paper machine remains to
be evaluated.

Screening and Cleaning

Coarse screens with holes and fine screens with slots are used to remove
contaminants, based primarily on their size [21-30]. Holes are generally 0.062
in. (1.55-mm or larger), although some screens are used with a O.055 in. (1.38
mm) hole size. Fine screens have slots with widths ranging from 0.008 in. to
0.024 in. (0.20 to 0.60 mm). It is important to remember that, as slot size
decreases, contaminant removal increases but so also does fiber loss [31, 32].
Moat pressure screens operate with mess reject ratios of 15-30%. TO
minimize fiber loss, second and third screening stages must be utilized. How
these stages are arranged is very important to the contaminant removal
efficiency of the system. In a conventional cascade system (Fig. 1),
re-circulation of contaminants between stages is quite common but this can be
detrimental to overall system efficiency. The use of a forward-flow
arrangement is recommended when ever possible to avoid this problem
[34,34,35,36].
One way of accomplishing a forward flow is shown in Fig. 2. Note that
both the primary end secondary stages have coarse end fine screens with
openings of identical size. Secondary slotted screen accepts are moved
forward. Depending on the nature of the furnish and concentration of
contaminants, a scalping screen (a coarse screen with a larger hole size then
those found in the primary or secondary stages) is used in the third stage,
followed by a coarse screen and fine slotted screen. By moving third-stage,
slotted-screen accepts forward, the re-circulation of contaminants has been
avoided. An added benefit is the reduced capacity requirements in all three
stages by not recycling accepts from the secondary or tertiary stages back to
the primary stage.
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After the screening operation, cleaners are used to remove contaminants

based on their density differences. Cleaners are classified as either high,
medium, or low density, with their use dependent on the density and size of
the contaminants they are removing. As shown in Table 2 [37], a high-density
cleaner is used to remove nuts, bolts, paper clips, end staples. These
high-density or forward cleaners are usually located immediately after the
pulpers. For medium-density contaminants, smaller-diameter hydrocyclones are
used. As the hydrocyclones diameter decreases. its efficiency in removing
small-size contaminants increases. For practical and economic reasons, the
3-in. (75-mm) diameter cyclone is the smallest cleaner used in the paper
industry.
Reverse hydrocyclones or throughflow cleaners are used to remove
low-density contaminants. A disadvantage of reverse hydrocyclones is that 55%
of the flow is constrained to the reject stream. Therefore, secondary and
tertiary stages are needed to recover the usable fiber [38]. This problem
does not occur in throughflow cleaners. The accepts end rejects come out at
the same end in throughflow cleaners. The reject stream is only 10% by volume
and 2% by mass[38, 39, 40]. However, the contaminant removal efficiency of
reverse hydrocyclones is usually higher than that of the throughflow
cleaners. Another problem with throughflow cleaners is that they are somewhat
prone to plugging due to the narrow gap at the exit. Rotating body cleaners,
introduced recently in North America, are effective for the removal of
low-density contaminents [41]. The reject ratio of these cleaners is so low
that there is no need for a second or third stage.
There are other types of cleaners available. One is the core bleed
cleaner where both high- and low-density contaminants are removed in a single
unit operation. High-density contaminants are removed through underflow while
low-density contaminants are concentrated in the center and removed through
the core tube. Accepts are removed through the annular space. These cleaners
are discussed further by Moreland [42].

Dispersion

The objective in dispersion is to break up contaminants end inks further

so they will be invisible in the final product [43,44,45]. Important
parameters to consider in dispersion are consistency, temperature, and
pressure. Consistencies of 25-30% are used while temperatures range from
160-180° F at atmospheric pressure. In some instances, higher temperatures
are used.
An application of dispersion is in breaking up waxes or hot melts in old
corrugated container (OCC) stock. Another application is in deinking of waste
paper furnishes. With the advances in printing technology, some of the newer
inks such se non-contact toner are believed to be bonded to the paper, end
these inks appear as specks in the final product. However, dispersion of ink
particles into smaller particles does decrease sheet brightness. When this
occurs, dispersion should be followed by en ink removal step to improve
brightness.
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Additives

A final strategy to combat stickies involves the use of chemical

additives. There are many different types of additives available on the market
end they can be classified according to their physical state end chemical
nature. Some of these additives include talc, solvents and dispersants,
cationic polymers, synthetic fibers, zirconium compounds, and alum
sequestering agents.

Talc

Talc consists of superimposed layers of magnesium sheets sandwiched

between two silica sheets. These layers are held together by weak van der
Waal’s forces, giving talc a soft and slippery feel. One of the important
characteristics of talc is its hydrophobic surface end hydrophilic edge. The
hydrophobic surface has an affinity for stickies while the hydrophilic edge
allows easy dispersion of the talc in water. In order for talc to be
effective, it should be es pure es possible because impurities will reduce the
affinity of the surface for organic material. Talc should be added to a deink
storage chest to allow time for the talc to contact end detackify the
stickies. About 0.6 to 1.9% of talc is generally used, based on o.d. weight of
the fibers. Talc is not effective on stickies which are riot tacky at the
headbox temperature but become tacky at the dryer temperature. It is important
that most of the talc be retained in the sheet so es to avoid excessive
concentration in the white water.

Solvents end dispersants.

Dispersants are classified as either anionic or nonionic

surfactants/polymers [5, 47-50]. Anionic dispersants keep small stickies
suspended in a slurry by inducing a negative charge on them which repels other
negatively charged stickies. Nonionic dispersants are generally long-chain
molecules with one hydrophobic end one hydrophilic and. When a secondary
fiber slurry is mixed with a nonionic dispersant, its hydrophobic end will
attach to a stickie, leaving the hydrophilic end exposed to water with no
affinity for stickies. Thus, agglomeration of stickies is prevented.
Dispersants mixed with appropriate solvents can help in the defibering of
wet-strength papers. Some dispersants are sensitive to pH,temperature, end
the presence of other chemicals end should be selected based on their
compatibility with the existing system. Environmental concerns like toxicity,
odor, end flammability should also be addressed when selecting these
chemicals.
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Cationic polymers

Stickies and other colloidal particles in the pulp slurry can be adsorbed
onto fibers by the use of cationic polymers [48]. These polymers can be added
at the thick stock chest, fen pump or at the headbox. The addition of cat ionic
polymers can thus avoid build-up of stickles in the white water system.
Another application of cationic polymers involves spraying them on paper
machine wires to minimize the deposition of stickies [51]. These polymers
passify the wire. Some products are also available for spraying on felts.

Synthetic fibers

Synthetic fibers, such as polypropylene fibers, have en affinity for ink

end organic contaminants and can be used to scavenge them from a system [7].
They are especially useful with tacky stickies. Like all additives, synthetic
fibers should be added well ahead of the headbox. The recommended initial
dosage is about 0.1%, based on o.d. fibers, increasing to 0.3% if necessary.
Synthetic fibers are effective only at the temperature and PH where stickie
tackiness is high. Therefore, like talc, synthetic fibers may not be very
effective on stickies which are not tacky at headbox temperatures but become
tacky at dryer temperatures. These fibers do not bond well with cellulose
fibers and may cause problems during paper machine operation. Because of this,
their use has been limited.

Zirconium compounds

Zirconium compounds detackify stickies from hot melts and

pressure-sensitive adhesives, with most of them ending up in the final product
[52]. Small amounts can also be found in white water due to their adsorption
on fines. These compounds are available in liquid form and any excess can
accumulate in the white water where they prevent the buildup of stickies due
to white water closure. Zirconium compounds are moat effective at high
dosages, with 1 kg/ton recommended. Like all additives, they should be added
as far upstream from the headbox es possible and should be selected for the pH
range of interest. They are not as effective in detackifying stickies when a
combination of hot melts and pressure-sensitive adhesives are encountered.

Alum sequestering agents

Alum is used to ensure good retention or uniform sizing. However, an

excessive amount can lead to coagulation of stickles in the secondary fiber
stock. Also, when the pH changes suddenly, excess alum can precipitate on
solid surfaces. Sequestering agents can be used to scavenge excess aluminum
ions which could later be available if alum concentration decreased [53].
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However, agglomeration of stickies occurs even in the absence of excess alum.

Stickies also accumulate and agglomerate in stagnant areas of tanks, pipes,
and partly open valves. In those cases, the addition of sequestering agents
will be of little help.

NEW TECHNOLOGY

High-shear-field separation under laminar flow conditions has been

investigated at the USDA Forest Products Laboratory. The results have been
reported in a series of publications [54-58]. Experiments to date have used a
disk geometry to demonstrate the separations possible with high-shear-field
separation. A disk separator with a 152-mm diameter end disk rotation at
around 5000- rpm exhibits good contaminant removal for many contaminants from
pulp slurries at up to about 1.0 percent consistency.
The researchers involved report that high-shear-field separation is
strongly indicated es a process for fiber recovery from reject streams from
papermills that recycle wastepaper. Subjecting the reject Pulp slurries to
high-shear-field separation se a final process step before discarding the
rejects could be beneficial to paper manufacturers in two ways.
First, the most obvious benefit for paper manufacturers would be the
combined reduction of disposal costs plus the value of the recovered fiber.
Ideally the recovered fiber would be sufficiently clean to feed forward in the
papermaking system. Failing that, the recovered fiber could be re-introduced
at the beginning of the stock preparation process for a complete stock
processing again. Another alternative would be for the recoverd fiber to be
sold to a nearby mill producing a grade with higher tolerances for
contaminants.
The second benefit would be in the amount of wastepaper, the quality of
wastepaper, or both that an efficient fiber recovery system would permit the
paper manufacturer to use. For most paper manufacturers, the coat of fiber is
the single highest manufacturing cost. An efficient fiber recovery system
would permit significant savings to the paper manufacturer by permitting the
manufacturer to purchase lower cost fiber.
Throughput capacity for a single 152-mm diameter disk is at 0.25 metric
tons per day on a dry pulp basis. Efforts to increase the throughput to
commercial scale throughputs of 3 to 5 metric tons (dry basis) using the disk
geometry have not been successful.

TEST METHODS

No single satisfactory contaminant-measuring method exists, nor has any

one method been widely adopted [59]. Factors that contribute to the
complexity of method requirements include the great variations between the
many wastepaper grades, which contain heterogeneous and ever-changing
contaminants, end the wide range of paper grades made from recycled
wastepaper. which vary vastly in their tolerance for contaminants. Also,
contaminant-measuring methods are used by different groups (for example, those
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engaged in manufacturing, technical service, and equipment development), and

each group has different masuring needs.
Usually stickie test methods are developed for a specific application. A
compilation of atickie test methods has recently been published by Forrester
[60]. He has compiled 11 methods in this group which cover the range of
methods usually needed. People in need of a teat method specifically designed
for a given situation can refer to these methods for ideas on how to develop a
suitable test method.
Ling end co-workers [61], modified a method originally developed by Doshi
[11]. The Ling method measures the weight of stickies attracted to microfoam
collectors from a pulp slurry. The Ling method has been used for three major
types of stickies: hot melts, contact adhesives, and laser inks.
Hacker [62], described a method for contrast enhancement of stickies in
handsheet samples prior to image analysis. The method used an aqueous ink to
dye the pulp fiber to enhance the contrast between stickies end pulp. Hacker
documents how the method was used to evaluate a stock preparation system
improvement for recycling old corrugated containers.

CONCLUSIONS

Stickies are one of the major problems encountered in recycling

wastepaper, many approached can be used for their control. These include both
mechanical methods (screening, cleaning, end dispersion) end chemical methods
(solvents, synthetic fibers, zirconium compounds. end other additives). By
understanding the kinds of stickies that maybe encountered end their
properties, their impact on the papermaking process end resulting product can
be greatly minimized.
In the future, cooperation and communication between representitives of
paper mills, equipment suppliers, manufacturers of inks, coatings, adhesives,
and chemical suppliers can greatly benefit the advance of recycling
technology. The ultimate goal should be to formulate inks, coatings, end
adhesives so that they are effective end economical and, at the same time,
allow for easy removal of stickies during the recycling process.

LITERATURE CITED
In: Rowell, Roger M.; Laufenberg, Theodore L.;
Rowell, Judith K., eds. Materials interactions relevant to
recycling of wood-based materials: Proceedings of Materials
Research Society symposium; 1992 Apri127-29; San Francico, CA.
Pittsburg, PA: Materials Research Society; 1992: 257-267. Vol. 266.

Printed on Recycled Paper