Helping the Corrugating Industry Improve Production

Volume 11 Issue 2 July 2002

New Harper Love Alliance in North America Joins Efforts and Succeeds at New Market
Successful Bonding of Corrugated Board containing a special waterproof coating
The technical departments of Corn Products, the U.S. business unit of Corn Products International, Inc., and its new alliance partner, Harper/Love Adhesives Corporation, recently teamed up to successfully bond corrugated board containing a special waterproof coating an achievement that is gaining notice throughout the box industry. This joint effort exemplifies how powerful our alliance with Harper/Love can be when we capitalize on our synergies, said Doc Kinney, technical sales service manager for Corn Products. Bonding corrugated board with this specialty coating had limited success in the past until we combined our efforts through the new alliance. Now, we have been completely successful at two separate locations, and word is spreading throughout the box industry of our team effort and accomplishment. We will continue to approach this market on a united front, capitalizing on the synergies and expertise of both companies. This special coating was developed to replace the old method of curtain coating the boxes with hot, liquid wax. Wax coated boxes are required in such industries as poultry, meat, fish and produce to ship the goods to the market. The wax acts as a waterproof barrier on corrugated containers, protecting the paper and the starch adhesive against extreme wet, humid or cold conditions. The use of wax to coat boxes has been in the negative spotlight in recent years, Kinney said. Wax boxes are not recyclable and must be disposed of in landfills, so they are not environmentally friendly. Many of the consumer goods stores, particularly supermarkets, must physically separate recyclable boxes from wax boxes and then pay up to $120 per ton to dispose of wax coated boxes. Replacing the wax boxes would eliminate the expense of separating the waste and actually contribute some income, as companies can sell their recyclable paper waste back to the paper mills as old corrugated containers. This new specialty coating is 100 percent recyclable, thus enabling end users to return all of their corrugated containers back into the paper cycle. This is a win-win effort, with the ultimate winner being the environment. Plastic containers have made a big push to be the end-all answer to the wax box, Kinney said. Plastic containers can be reused and recycled. However, they have their own inherent problems in some of the markets that corrugated boxes serve, he said. Plastic containers take up valuable warehouse space, whereas a corrugated box can be broken down or crushed into space. Companies that rely on plastic containers must invest in cleaning and sanitizing these containers if they are to be used in food handling. On the other hand, corrugated board can be used once and sold as recycled paper. Plastic is also impervious to air, whereas corrugated containers can breathe, allowing fruits and vegetables to have access to natural

CornProducts
I N T E R N AT I O N A L

or controlled atmospheric conditions. Containers made of plastic are also very rigid, while corrugated paper has a cushion effect that provides some shock absorbency to delicate contents. There is a concerted effort by the paper industry not to lose this specialty waterproof market to plastic, Kinney said. We were fortunate to be on the forefront of this trend and have the alliance with Harper/Love to answer the market needs. We combined Corn Products Fiberbond specialty carrier starch and the Harper/Love Aquaseal waterproofing resin to produce waterproof corrugated board that was tested in the TAPPI laboratory at Moffett and determined as fit-for-use in extreme conditions. We approached and conducted the trials through a well-coordinated technical effort and an execution that resulted in great success. We are now pursuing several more opportunities as customers continue to hear about our joint success. For more information about this specialty coating, please contact your Corn Products representative.

Inside:

New Harper Love Alliance in America

Know the secrets to success for papers with functional coatings

Someone You Should Know

TAPPI Tour Draws 25 to Argo Plant Troubleshooters Notebook

p a c k a g i n g

Know the secrets to success for bonding papers with functional coatings
By Doc Kinney Technical Services Manager, Corn Products breathingand the higher the porosity value. In addition, the types of functional coatings that are applied will also affect the porosity of the paper. As the porosity values of paper increases, the penetration of starch adhesive into the paper correspondingly decreases. In many instances, the use of specialty carrier starches in combination with bond enhancing liquids are an excellent approach to quality bonding of papers with functional coatings. Since the porosity of the paper is effectively reduced, the penetration of the adhesive is reduced, resulting in a surface bond. This surface bond must be strong enough to hold the sheets of paper together through the torture of the flexos, folders and, ultimately, the end user. The best assurance of a quality bond is the use of specialty carrier starches and bond enhancing liquids that work together to provide a strong glue. When a box maker investigates a new market using papers with functional coatings, it is a good idea to consult the starch suppliers technical service staff. The technical service managers at Corn Products can recommend the proper adhesive and operating conditions for applying functional coatings. In addition, Corn Products operates a well-staffed TAPPI laboratory that can analyze both the paper and the finishes of boxes to measure the success of the bonding process. Corn Products technical support laboratories are staffed with chemists and personnel who are experienced in papermaking and corrugating and are dedicated to customer support. For more information, please contact your Corn Products technical services representative.
When it comes to building relationships with customers, Corn Products customer service team is essential to maintaining satisfaction with the quality of service that Corn Products provides. Our customer account agents and contract-billing analyst are integral to meeting any and all of our customers needs, from placing an order to ensuring that the order is delivered on time,said Dave Rotondi, Manager of Customer Service, for Corn Products. The customer service center team consists of four customer account agents (CAAs) who are each responsible for monitoring and supporting customer needs in a specific geographical region. In addition, a contract/billing analyst (CBA) serves as the senior resource person for the department, setting up new accounts and managing all aspects of the billing process. Corn Products customer account agents monitor all product deliveries and oversee the entire order cycle. Customer account agents play a critical role in managing customer orders from beginning to end as well as resolving any unforeseen problems in the middle. Additionally, the CAAs oversee inventory for certain strategic geographic locations, ensuring that the inventory at each location is sufficient to fulfill customer needs, Dave said. We manage inventory through break stations, strategic points across the country where rail cars are placed to fulfill customer orders quickly and easily. One of the most important aspects of service delivery is responsiveness to callers. In todays world, many companies have adopted a menu path technology of managing incoming calls. At times, this technology can become very confusing and frustrating, Dave said. At Corn Products, we have remained committed to the personto-person interface of managing incoming calls and we do it in an exceptional mannerour average speed in answering an incoming call is less then 5 seconds! he said. This is something we are very proud to have achieved.

The days of typical brown boxes are behind us now. Today, linerboard and containerboard companies are seeking to add value by developing papers with functional coatings that enhance printing quality, impart anti-skid properties, provide wet strength and/or dry strength and much, much more.

As more functional coatings are developed and incorporated into the linerboard and medium, the papers physical properties also change. These changes in paper characteristics are important for the corrugator to recognize in order to effectively bond the medium to the liner so that the finished box will stay intact and provide value for the end user. In many instances, the functional coatings that are added to linerboard and medium significantly impact the porosity of the paper. Porosity is the measure of how open the fibers in the paper are. You might think of porosity as how compacted the fibers are and how well can the paper breathe. Porosity is a time measurement of how quickly a set volume of air can pass through a sheet of paper. The more tightly compacted or oriented the fibers are, the less the paper is capable of

Justine Lietz, Customer Account Agent: Justine has been with Corn Products for 13 years, and has held five different positions within the company. Seven years ago, she joined the customer service center team at Corn Products and brought with her the working knowledge of many internal departments. I originally supported the Southeast region for four years and presently support the Midwest region, she said. I enjoy the variety of customer personalities and the challenge of getting things done right and efficiently. Justine also enjoys bike riding, crafts and antiquing.

Dave Rotondi, Manager, Customer Service: As the leader of Corn Products customer service center, Dave considers his most important role to be a resource for members of his team. When there are roadblocks that make it difficult for the people on my team to perform their jobs as efficiently as possible, I offer the support they need to eliminate the obstacles they might face, he said. Dave enjoys the variety of work and the active participation that is needed on a daily basis. In addition to the challenge of fixing the unexpected, I truly enjoy helping each member of my team attain personal and professional growth, he said. I enjoy these opportunities because I can be a coach, counselor, or a leader, and help them to be better people and, thus, become better employees. Dave also enjoys handyman projects around the house and spending quality time with his wife and two daughters.

Wanda Harper, Customer Account Agent: Wanda became a member of Corn Products customer service team seven years ago. She supports the Northeast region of the US. I really enjoy servicing my customers needs. We work in an environment that demands quick actions in critical times. I welcome the role I need to play to troubleshoot situations for our customers after all, we are their advocate. In her free time, Wanda enjoys outside activities like, bike riding and nature walks. She also enjoys roller-skating.

Pat Labun, Customer Account Agent: Pat has worked for Corn Products for more than 18 years, working as an administrative assistant and customer service representative at the Corn Products plant in Stockton, Calif. Nearly seven years ago, she relocated to Chicago to become a CAA for the West region and currently supports the Southeast. My customers are great! I also enjoy the diversity of the job serving different areas of the country to support the needs of the industry, she said. In her free time, Pat works as an ESL (English as a Second Language) teacher for DuPage County, IL, and is a volunteer at the Peoples Resource Center in Wheaton, IL. She enjoys gardening and travel.

Kim Schoot, Customer Account Agent: Kim supports the West Coast region and Puerto Rico. She joined Corn Products five years ago and has worked in the Customer Service Center the entire time. Kim came to the company with a solid foundation in customer service, having gained 10 years experience from other companies in the customer service arena. I like problem solving and I enjoy serving others, she said. Outside of work, I coach my teenage daughters softball team. I also enjoy gardening.

Pat Sexton, Contract/Billing Analyst: Pat celebrates her 32nd anniversary with Corn Products this year. Pricing became part of customer service in 1996 with the implementation of the SAP system. I have been doing pricing since 1988, when Corn Products headquarters moved to Bedford Park from Englewood Cliffs, she said. I enjoy my job because things are always changing no two days are ever the same. Pat also coaches a peewee cheerleading squad for girls between the ages of 6 and 9, and serves on their board of directors. She recently became involved with the Junior Achievement program through her work at Corn Products. I knit, crochet and generally enjoy any type of craft, she said.

TAPPI Tour Draws 25 to Argo Plant

Twenty-five corrugating professionals from the Chicago area gained a firsthand look at Corn Products internal operations during a Chicago TAPPI Conference tour that took place in early May. Representatives from the Chicago TAPPI Conference were invited by Corn Products to visit the companys U.S. headquarters in Bedford Park, IL, as well as tour the laboratory, manufacturing and shipping areas of Corn Products Argo plant.

Tr o u b l e s h o o t e r s N o t e b o o k
Q
What precautions should be taken when using wastewater?

The Chicago TAPPI conference periodically sets up workshops for its members to learn more about developments in the corrugating industry. This year, Chicago TAPPI decided to take its presentations on the road by visiting our members facilities, said Al Bromberek, technical sales service manager for Corn Products, who is also a member of the Chicago TAPPI Conference Board. The event began in the public library near Corn Products headquarters, where participants were treated to an overview of Corn Products US and global operations, its commitment to the industry, and the many different products that Corn Products manufactures. Next, the group headed to the Argo plant for a detailed tour of the companys TAPPI lab, analytical lab and wet lab; watched as starch was centrifuged and dried; walked through the packaging section of the plant, and were taken on a driving tour of the plants corn unloading and refinery areas. During each portion of the tour, representatives from throughout Corn Products were available to answer questions in their area of expertise. I thought the Chicago TAPPI tour of the Argo plant was an extremely impressive sales tool. It gave Corn Products the opportunity to showcase our starch manufacturing process, said Dennis Callanan, director of industrial sales for Corn Products. The tour of our analytical and support labs and customer service department served as a testament to our commitment to supply and service the corrugating market. After the tour, participants enjoyed refreshments that were made using Corn Products specialty products, such as various soft drinks and cookies. Door prizes included Corn Products collectibles such as golf balls, hats and other premium items. Reviews of the event were very positive, Bromberek said. Everyone I talked with about the presentation really enjoyed it, he said. One of the managers said he drives by our plant every day as he drives down Interstate 55 and never really thought about what goes on there. This tour has given him a new perspective. He was very impressed with our operations.

The use of wastewater by corrugating plants is particularly popular on the West coast and is beginning to become more widely used in the Midwest and on the East Coast. More and more corrugating plants are using wastewater as the secondary water portion in their adhesive formulations because of its benefits to the environment, said Randy McDaniel, technical sales service manager for Corn Products. There are two types of wastewater: treated and untreated. Treated wastewater is filtered through a specialized system using pH controls. Untreated wastewater is raw, dirty, black water that usually consists of inks, oils and detergents that have been washed up during the cleanup process. Treated wastewater is more forgiving, because the solids have been pressed out of it. This type of wastewater is balanced with chemicals to make it as close to tap water as possible, McDaniel said. In untreated wastewaster, the pH is inconsistent and the solid content will vary depending on how well the cleanup process was performed. Both of these factors are going to vary from location-to-location on a day-today basis. The biggest problem that plants face in using untreated wastewater is inconsistency in the viscosity of their adhesives. We ll get calls from customers who are having difficulty maintaining the right viscosity in their adhesive formulations, and most of the time, it s a water issue, not a starch issue. While treated wastewater is more expensive than untreated wastewater, the benefits of a stable pH and reliable solid content often outweigh the extra cost involved. I recommend not using untreated wastewater, McDaniel said. You just don t know from day to day what you re going to get. But if untreated wastewater is the company s preference, McDaniel recommends that the company direct an employee to monitor every batch that is being produced in order to quickly spot potential problems in the formulation of the adhesive. A manual check of the viscosity and gel temperature should be performed with every batch, he said. The pH of the water should also be checked daily. It s also a good idea to document the wastewater temperatures on a daily basis, so that you have a record of the conditions for each day and the types of inconsistencies you may have experienced. For more information about the use of wastewater, please contact your Corn Products technical service representative.

Corn Products International

Headquarters:
Moffett Technical Center 6500 Archer Road Bedford Park, IL 60501 1(800) 443-2746

Casco Head Office:

401 The West Mall Etobicoke, Ontario M9C 5P7 (416) 620-2300

This bulletin is intended as a resource on starch and its relationship to and use in corrugating. The information presented is based upon actual field and laboratory work. However, it should not be viewed as providing advice or solutions to particular applications, each of which will be unique and not susceptible to general advice. We encourage you to call your representative at Corn Products or Casco to discuss your specific situation. We will be happy to lend our support.

2002 Corn Products International, Inc.

Printed in USA 7-01-02 1000