March/April 2012

www.pulpandpapercanada.com

Nanocrystalline
cellulose
The small product with
big ambitions grows up

PaperWeek Canada highlights

New product, new attitude at Thurso
Which is the safest mill in Canada?

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March/April 2012 Vol. 113, No. 2 A Business Information Group Publication

PRINT EDITION ISSN 0316-4004 ON-LINE EDITION ISSN 1923-3515
PAPERWEEK CANADA HIGHLIGHTS 16

COVER STORY

12 Made-in-Canada Nanotech
Canadian research and
engineering have culminated in
the first industrial-scale production
of nanocrystalline cellulose (NCC).
Read how CelluForce came to be.
CELLUFORCE START-UP 12 DISSOLVING PULP SUCCESS 10

FEATURES

10 Turnaround at Thurso
The conversion to dissolving pulp at Thurso is complete. Fortress Specialty
Cellulose has new equipment, a new product, and a new attitude.

16 The Best of Both Worlds at PaperWeek Canada

REFINING UPDATE 26

Emerging technologies shared the agenda with traditional pulp and paper
topics when the industry gathered at PaperWeek Canada. If you missed the IN EVERY ISSUE
conference, catch up on business trends, biorefining, technical papers and
award-winners here. 4 Editorial
6
23 Safest Mill in Canada: Working Together for the Safety of All
News

Winners of the 2011 Safest Mill in Canada contest share their thoughts 26 Technology News
on how to implement a culture of safety in the workplace. Also, see the Refining
detailed results of the 2011 contest. 27 Technology News

30 Opinion: Silver Lining to Fine Papers Decline 29 Classified Ads

Glenn Clifford tallies the deterioration of Canadas fine papers segment,
and calls for investment to shift the industry toward growth markets. MISSION STATEMENT:
To promote the pulp and paper industry in
Canada by publishing news of the people
and their innovations in research, technology,
management and financing, as well as
For breaking news, visit www.pulpandpapercanada.com forecasts of future trends.
Serving the industry since 1903.

pulpandpapercanada.com March/April 2012 PULP & PAPER CANADA 3

 EDITORIAL

EDITORIAL
Editor
CINDY MACDONALD

Mill towns face tough

416-510-6755
cindy@pulpandpapercanada.com

choices
ADVISORY BOARD
Richard Foucault Sustaining member, Pulp and Paper
Greg Hay Technical Association of Canada;
Dr. Richard Kerekes Member, Canadian Business Press and

T
Barbara van Lierop
he major union representing Canadian pulp and paper Dr. David McDonald
workers says there are about 300 forestry-dependent towns Dennis McNinch
Dr. Yonghao Ni
across Canada. Many of those have been on tenderhooks this Bryant Prosser
fall and winter, wondering about the fate of mills that are Dr. Paul Stuart
Ross Williams
either closed, or on very shaky ground.
Much as industry leaders like to put a positive spin on the ADMINISTRATION
Interim Publisher
transformation of the industry (as was in evidence at Paper- JIM BUSSIERE
Week last month), the restructuring has been brutal on the jim@pulpandpapercanada.com
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Audit Bureau of Circulation.
Indexed by: Canadian Business
Periodicals Index; Abstract Bulletin,
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Technology; Materials Science
Citation Index
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Editor

4 PULP & PAPER CANADA March/April 2012 pulpandpapercanada.com

 INDUSTRY NEWS

Catalyst Paper clears hurdle: both Crofton unions approve deal

Both union locals at Catalyst Papers Crofton, B.C., mill
have voted in favor of a new contract. Members of the Pulp,

Photo courtesy Catalyst Paper.

Paper and Woodworkers of Canada local at Crofton turned
down a previous contract proposal in January, and pushed
Catalyst Paper into creditor protection.
The current vote in favor of the collective agreement
allows the papermaker to proceed with a restructuring plan
and work toward exiting creditor protection.
The agreements, which will be effective from May 1, 2012
to April 30, 2017, include a 10% reduction in hourly rates
along with various adjustments to vacation, health benefits
and work rules necessary to provide Catalyst with a com-
petitive labour cost structure. The agreements also maintain
hourly retiree health benefits. Annual savings in the range of
$18 to $20 million are expected.
According to a local news site, HQcowichanvalley.com,
the president of Local 1132 of the Communications, Energy
and Paperworkers Union, Fraser McQuarrie, said a majority
of union members consider their contract the lesser of two
evils--better than having the mill sold to a new owner with
an uncertain future.
Catalyst Paper manufactures diverse specialty mechanical
printing papers, newsprint and pulp. It is operating under
creditor protection while restructuring.
Employee approval of the new collective agreement
allows Catalyst Paper to move forward with its
restructuring plan.

Cascades closes packaging plant
in Toronto
Continuing its consolidation, packaging
and tissue manufacturer Cascades Inc. has
permanently closed Cascades Enviropac,
located in Toronto.
Production at this unit specialized
in the manufacturing of Technicomb
honeycomb packaging, intended primar-
ily for the furniture packaging industry.
The closure will be effective June 1, and
affect approximately 36 employees.
Fortress buys Lebel-sur-Quevillon
mill for dissolving pulp
Fortress Paper is planning a second pulp
mill conversion to dissolving pulp, this
time targeting the mothballed Lebel-sur-
Quevillon mill in northern Quebec owned
by Domtar.
A wholly-owned subsidiary, Fortress
Global Cellulose Ltd., has signed an asset
purchase agreement to acquire the build-
ings, equipment, and ancillary property
for the nominal amount of $1. The mill
has been closed since 2005. The company
intends to spend $222 million to convert
the Lebel-sur-Quevillon NBSK mill to a
dissolving pulp operation with an associ-
ated co-gen facility.
The mill will have an annual produc-
tion capacity of approximately 236,000
air dried metric tonnes (ADMT) and is
expected to be completed in late 2013.
The companys other dissolving pulp
conversion, at Thurso, Que., came on
stream in December 2011.
FPInnovations reorganizes to be
strategic partner for industry,
government
FPInnovations has made a series of chang-
es to better position the organization as
a strategic partner to industry members
and clients, federal and provincial govern-
ments, and the larger research community,
especially universities.
FPInnovations will keep a strong
hold on R&D through its collaborative
research with forest industry members.
To this, it adds a business development
component which encompasses strategic
research alliances, products and services;
and licensing and ventures.
I am convinced that this is the right
move for FPInnovations. These changes
will help us explore new partnerships with
energy and chemical industries to name a
few, stated FPInnovations president and
CEO Pierre Lapointe.
Building the future labor force
Developing effective, local partnerships
with Aboriginal peoples will be a criti-
cal factor in helping the Canadian for-
est products sector address future labour
force requirements, states a new report
from the Forest Products Sector Council
(FPSC-CSPF).
Conversation and Collaboration: Build-
ing the future Canadian forest products sec-
tor with Aboriginal talent highlights the
challenges the sector faces and how it can
move forward in engaging with Canadas
Aboriginal populations.
Several key strategies are proposed:
develop effective youth education
programs and Aboriginal-specific

6 PULP & PAPER CANADA March/April 2012 pulpandpapercanada.com


People
Thanh Trung is joining FIT-
NIR Analyzers as vice-president
of technology. Tom Sands, presi-
dent, says, His extensive knowl-
edge and experience in mill opera-
tions as well as his technical exper-
tise in vibrational spectroscopy are
true assets to FITNIR and to our
customers. FITNIR Analyzers
Inc. is the global distributor of the
near infrared (NIR) liquor analyz-
ers developed by FPInnovations.
Dr. Cyril Heitner, a long-time
FPInnovations scientist, has been
named a TAPPI Fellow. Fel-
low is an honorary title bestowed
upon individuals who have made
extraordinary technical or service
contributions to the industry.
Heitner joined Paprican (now
FPInnovations) as an Industrial
Post-doctoral Fellow in 1970,
became a member of the staff in
1972 and worked there until his
retirement in 2006. Dr. Heitners
scientific achievements are in the
area of lignin modification to pro-
duce high quality ultra high-yield
pulps. He contributed to research
on the effects of sulfonation on
lignin softening, fiber length dis-
tribution and interfiber bonding.
resources to promote careers in the
Canadian forest products sector;
produce Aboriginal labour market
information;
support and grow successful training
programs and partnerships between
Aboriginal groups and industry.
To access the report, visit www.fpsc-cspf.ca.
RockTenn closes highest cost
containerboard mill in Matane,
Que.
RockTenn has permanently closed its
Matane, Que., containerboard mill, say-
ing it was the highest cost mill in the
RockTenn containerboard mill system.
RockTenn acquired the Matane mill in
May 2011 as part of the Smurfit-Stone
acquisition. The closure will put more than
100 people out of work.
The facility is equipped to produce
176,000 tons per year of recycled cor-
pulpandpapercanada.com March/April 2012 PULP & PAPER CANADA
Briefly
Prospective buyers have been
touring the Terrace Bay mill in
Northern Ontario, while in Nova
Scotia, the bidder on the NewPage
pulp and paper mill is ironing out
details with the provincial utility
and the employees union.
Buckman has been selected as a
Hay Group Insights (HGI) High
Performing Company for 2011. In
its executive report to Buckman,
HGI indicated that Buckman is
an ethical and socially responsible
company, with a clear sense of
direction and strong leadership. It
also noted that Buckman fosters
a culture that supports teamwork
and collaboration.
rugated medium. RockTenn ceased pro-
duction at the mill in late January 2012.
According to the Le Soleil newspaper,
the mill is for sale, but because of a non-
competition clause, others in the field
have little interest in the assets.
Forest sector CEOs expect to cut
costs and change strategy in 2012
Nearly half (48%) of the 1,258 CEOs
polled worldwide believe the global econo-
my will decline even further in the next 12
months, according to PwCs 15th Annual
Global CEO Survey. Just 15% said the
global economy will improve during 2012.
PwC also released a sector summary of
the CEO survey geared to the forest, paper
and packaging (FPP) sector. The data is
based on interviews with 49 forest, paper
and packaging CEOs in 23 countries.
FPP CEOs are markedly more likely
to keep a tight rein on costs than their
counterparts in other sectors. Eighty-four
percent have implemented a cost reduc-
tion strategy over the past 12 months, and
almost as many (82%) expect to trim any
remaining fat in the next 12 months, says
the PwC report. Only 66% of CEOs in
the total sample plan to make cost cuts.
The survey also notes that 37% of FPP
CEOs intend to reduce their companys
staffing over the next 12 months.
CEOs in the forest, paper and packag-
ing sector are also twice as likely as their
fellow CEOs to be planning to make major
INDUSTRY NEWS
divestments or exit from significant markets
in the coming year. As well, 63% anticipate
changing their corporate strategy this year.
Another notable difference is that FPP
CEOs are more focused on developing
new products and services than the overall
sample (37% vs. 28%).
PwC is a global organization with exper-
tise is assurance, tax and advisory services.
Domtar negotiates $3-billion,
15-year deal to supply paper to
Appleton
Photo courtesy Domtar.
Domtars John D. Williams says the
Appleton deal provides an opportunity
to repurpose some paper capacity.
Appleton and Domtar Corp. have reached
an agreement in which Domtar would sup-
ply Appleton with most of the uncoated
base paper the company needs to produce
its thermal, carbonless, and other specialty
paper products. The historic 15-year supply
deal is valued at more than $3 billion over the
life of the agreement. Appleton is one of the
worlds leading specialty coaters, and while
Domtar is the largest integrated manufac-
turer of uncoated paper in North America.
Integrated is the key word here.
Explaining the deal, Mark Richards,
Appletons chairman, president and CEO,
said that non-integrated paper mills, those
not capable of producing pulp from logs or
wood chips, are distinctly disadvantaged
and no longer competitive.
John D. Williams, Domtars president
and chief executive officer, stated, This
proposed agreement provides us with an
opportunity to repurpose and replace high
volume communication paper capacity to
specialty paper grades, while securing a
growing business long-term.
Indeck takes on Ameritek as
Quebec representative
Boiler systems provider Indeck is now
represented in Quebec by Ameritek.
French Canadian pulp and paper mills,
7
 INDUSTRY NEWS

manufacturers, refineries and processors
now have a regional contact to expedite
their boiler requirements. Indecks man-
ufacturing and distribution capabilities
include rental and stock boilers to 300,000
PPH or custom boilers to 1,000,000 PPH.
Indeck has a well established Cana-
dian presence with its St. Hyacinthe,
Que., manufacturing plant, formerly the
Volcano Boiler plant.
Ameritek is located near Montreal in
Saint-Lambert, Que.
Canadian engineer free after six
months in jail
Pulp and paper engineer Rick van Lee was
freed from jail in Indonesia following an
appeal to the High Court in Pekanbaru.
On Feb. 2, the court changed van Lees
sentence to six months (which equaled
time served) and released him.
According to the web site www.freerick-
vanlee.com, which was established to rally
support for van Lee during his trial, the
engineer and his wife have left Indonesia.
In December 2011, van Lee was sen-
tenced to three years in prison for theft of
confidential company data. He had been
working for Asia Pacific Resources Inter-
national Limited (APRIL) at the time of
his arrest. The case involved allegations
that van Lee used private storage media
for safekeeping company data.
During his 37-year career, van Lee has
worked for global consulting engineering
companies such as Amec, Ausenco, KSH
Solutions, and Poyry, as well as equipment
suppliers and pulp and paper producers.
Wood fibre costs declined in Q4,
likely to continue dropping
Global demand for pulp has declined
and pulp prices fell during the second
half of 2011.
As a consequence, prices for wood
fibre, the highest cost component when
producing pulp, were down throughout
the world, reports the Wood Resource
Quarterly. The organizations Global
Wood Fiber Indices for softwood and
hardwood fiber declined 3.5% from the
third quarter of 2011.
There has been a long-term trend in
the pulp industry of wood costs increas-
ing as a percentage of the total production
costs. In the third quarter of 2011, this
share had reached 63.5% on a worldwide
basis, up from only 53% in 2005, accord-
ing to Fisher International.
However, this share can vary substan-
tially, from a current low of 52% in East-
ern Canada to as high as 73% in China.
Wood fiber costs are likely to continue
downward in a number of markets in
the first quarter of 2012, particularly in
the Nordic countries, Western Canada
and the US as pulp prices continue to be
substantially below the record-high levels
from last summer.

PacWest Focuses on Sustainability through People and Technology

PacWest, the annual industry gathering for Western Canada,
moves back to Jasper this year. The four-day event has also
changed its time slot, moving up to May 30-June 2.
Organized by the Pacific and Western Branches of the Pulp
& Paper Technical Association of Canada (PAPTAC), PacWest
will offers pulp and paper personnel a great opportunity for
upgrading their knowledge and skills, as well as networking with
peers. The annual conference and trade show incorporates techni-
cal presentations, short courses and round-table meetings for mill
managers, maintenance managers and pulp mill superintendants.
The conference forum on Thursday, May 31, will have
the theme Sustainability Through People & Technology.
Speakers include: Andrew Casey, Forest Products Association
of Canada; Tom Johnstone, Buckman Canada; Jean Hamel,
FPInnovations; and Wade Chute, Alberta Innovates Tech-
nology Futures.
Fridays keynote presentation continues the sustainabil-
ity theme, with John Wright, senior vice-president of market
research firm Ipsos-Reid, addressing technology and people in
the pulp and paper industry.
Technical paper presentations will take place Thursday and
Friday, on the subjects of kraft pulping; environment, sustain-
ability and energy; process control; mechanical pulping; and
human resources development.
A tour of the Hinton Pulp mill is also offered on Thursday.
Concurrent with the technical session are roundtable meet-
ings for maintenance managers (May 30-June 1) and pulp
machine superintendants (June1-2).
Course offerings this year are all one-day training sessions,
on May 30. Brian Gallagher of GL&V will present a course on
Mill managers talked about their progress with Green
Transformation Program projects at PacWest 2011.
Brown Stock Washing & Screening. Participants will learn how
to evaluate and improve system operations and results. Continu-
ous Cooking Principles and Practices will be taught by Philip
Anderson of Metso. The course will enhance the basic knowl-
edge and skills of operating and technical personnel, and provide
practical approaches to help address common operating issues.
A third course option is Process Control Optimization an
Introduction, by Doug Nelson of ProNamics Control Inc. Par-
ticipants will learn to recognize poorly performing control loops
and how to improve performance. Mill optimization examples
and computer simulation demos are used.
On the social side, theres a 5 km run planned for Friday,
the awards dinner and dance Friday night, and golf plus a
barbeque on Saturday.
The trade show runs for three days, Wednesday to Friday.
For more details, visit www.pacwestcon.net.

8 PULP & PAPER CANADA March/April 2012 pulpandpapercanada.com

 Cleaner results
with inspired insight on site.
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profile too.
Thats why Tapio Pajari is on a European mission for Eka Purate,
our patented concept for generating chlorine dioxide on site.
Effective on microbes and spores, it removes and prevents the
formation of biofilm and slime deposits on surfaces and filters.
Always a paper technician at heart, Tapio simply wants mills to
experience the immediate benefit of pure water fewer holes
www.eka.com
and spots in their finished product, thanks to cleaner white water
and shower spray systems. And of course, increased runnability
and lower cost!
The brilliance, Tapio says, is that Eka Purate works with virtually
every process hes come across during his twenty years in the
business. It also makes good business sense, since the offsite
monitoring allows you to concentrate completely on what you
do best.
Inspiring paper all over the world is our inspiration.
Meet us at eka.com.
 MILL PROFILE
Turnaround at Thurso
The conversion is complete: the Fortress Specialty Cellulose mill in Thurso, Quebec, has
new equipment, a new product, and a new attitude.
By Cindy Macdonald , Editor
W
e dont see our self as a traditional pulp and paper
company, says Marco Veilleux, chief operating
officer of Fortress Specialty Cellulose. Well,
neither does anyone else, Marco.
The revival of the former Fraser Papers kraft mill in Thurso,
Que., is anything but typical. In 2010, Fortress Paper, with entre-
preneur Chad Wasilenkoff at the helm, bought the idled hard-
wood kraft mill for a pittance from its insolvent owner, Fraser
Papers. Wasilenkoff put the mill into the hands of Peter Vinall,
a veteran of the dissolving pulp business, and less than two years
later, the site is humming with vitality producing a high-quality,
high-value specialty product.
The creation of Fortress Specialty Cellulose, of which Vinall
is president and CEO, involved more than just equipment
changes at the mill. It involved a change in attitude among
employees. Dissolving pulp is really more like a chemical prod-
uct than a traditional pulp grade, and so a different level of
attention to the process is required.
And, between the lean mentality of Fortress Paper, and
Vinalls belief in empowering people, employees are becoming
accustomed to presenting ideas and then acting on them.
We are trying to create an empowered culture, says Vinall.
Fortress is a lean and mean company, with no bureaucracy and
fast decision-making.
Veilleux confirms that the paradigm shift has filtered down
to all levels of the company.
The level of pride is going up, people are looking to the
future. The restructuring process was very painful, but the
An elevated pipe bridge connects the new cooking plant to
the mill. The need to pump the liquid to such a height caused
some design headaches.
10 PULP & PAPER CANADA March/April 2012 pulpandpapercanada.com
majority of people have turned the page. People are getting
engaged.
And we allow people to make mistakes. Were learning every
day, he notes.
The biggest change is the sense that were building a future,
not just buying time [until the mill closes]. Its a major shift.
Merry (busy) Christmas
That sense of pulling together was evident in late December
when the mill eased into full operation. The actual start-up took
place over the Christmas/New Years holiday season. Veilleux
says the timing forced our people at the mill to jump in and take
ownership, and thats why the growth in production was so fast.
One month after start-up, the mill was producing about 70% of
its targeted production rate.
It really showed the commitment of our people, Veilleux
says proudly. We were having technical meetings Christmas
Eve, Christmas day. Not one person complained.
Fortress chose Superbatch technology from GLV for the
cooking process. Then, says Vinall, we used our experience and
invested money in the areas we knew would be bottlenecks.
That included the lime kiln and recovery boilers.
Fortress decided to purchase used equipment from a mill in
Finland, in order to speed up the mill conversion. The equip-
ment was dismantled and shipped to Montreal. From there, the
larger pieces were barged up the Ottawa River.
The 15-month conversion project was beset by the usual
construction issues, and some unique hurdles.
Housing the new cooking plant in a separate building outside
of the existing mill helped to overcome some of the headaches
involved with maintaining production during the construction
phase, but it created other trials. Discharge piping from the
digesters has to rise the full height of the building to exit at
the top through an enclosed pipe bridge that traverses a set of
railway tracks.
As the cooking plant came online, hammering in the dis-
charge pipes emerged as problem.
Then there was the unpleasant discovery that an older section
of the chip conveyor had to be redesigned and repaired.
And finally, in October, when a peak of about 900 con-
struction workers were on site and kraft pulp production had
already been shut down, the Quebec construction unions
staged strikes to protest a piece of provincial legislation, and
work came to a sudden halt for almost a week.

Dissolving pulp vs. kraft
The dissolving pulp process differs from kraft pulping in that
a pre-hydrolysis stage breaks down the bond between hemi-
cellulose and cellulose. Then the kraft cooking separates the
cellulose and lignin.
Hemicellulose and lignin are both going to the recovery
boiler, so if we had left them as is, it would be a bottleneck,
Vinall explains. Hence the $15-million investment to upgrade
both recovery boilers.
Dissolving pulp also needs more recaust capacity to balance
the whole mill at the best level.
After cooking, the pulp goes to a blow tank, then gets
washed. The cellulose is then bleached. Vinall says this mill has
good cleaning and brightening capability. With dissolving pulp,
the chemistry of bleaching changes, he explains. You have to
control viscosity and eliminate impurities.
A lot of work remains to be done on quality control and
process control. Theres a lot to know. We had to bring in the
right people, align with the right suppliers.
Theres not a lot of expertise out there in dissolving pulp.
To illustrate the sensitivity of the dissolving pulp process,
Vinall recalls a recent incident. One little gasket in the cooking
plant led to six hours of downtime. It took three hours to get the
quality back in balance. But on the other hand, it gave staff an
opportunity to work on the dryers.
As part of the conversion, distributed process control for the
fibre line was upgraded, and OSIsofts PI system was installed
to monitor quality control. As well, a new chemical testing lab
was set up, and technicians hired.
Modifications were also made in the loading dock. The
tolerance for the weight of bales is much tighter with dissolving
pulp, so baling equipment had to be upgraded. Fortress also
invested in a new unitizer, which wraps six bales into a bundle.
The unitizer saves $7 per tonne compared with having the work
outsourced.
All finished bales are kept in the shipping area at least 24
hours until all the product quality tests are completed.
Green energy helps offset costs
The question is, can a small, Eastern Canadian mill be competi-
tive in the global dissolving pulp market? Apparently so. At an
industry event last spring, Wasilenkoff said he expects produc-
tion costs to be about $650 per tonne. At the time, dissolving
pulp was selling for about $1800 per tonne. It has since settled
to approximately $1200.
Vinall explains that a number of factors will contribute to
Fortresss low production costs.
He notes that the mills supply of hardwood is rich and ade-
quate, but while the mill has acceptable wood costs compared
with the rest of Canada, in global terms, its higher than average.
So we need an offset, he comments. The bioenergy deal
with Quebec Hydro provides that. We buy energy at dirty
power rates, and will sell the energy we produce at green rates.
That is about a $100 per tonne benefit.
Thursos co-gen plant is under construction and expected to
come online in 2013.
The mills labor costs are below the national average, says
pulpandpapercanada.com March/April 2012 PULP & PAPER CANADA
MILL PROFILE
Peter Vinall, Robert Salt and Luc Timbers on the loading dock
where bales are loaded onto railcars. Most of the plants
output is taken to either Montreal or Trois-Rivires, shipped
across the Atlantic and then forwarded to China.
Vinall, and the site has good productivity. There were conces-
sions in the contract negotiated when re-opening the mill, and
Fortress has no legacy costs from the previous owner.
So if you add it all up, were in the first quartile, cost-wise.
Do what youre good at
Fortress Specialty Cellulose also has the benefit of an experi-
enced and talented management team. Vinall has 30 years of
experience, most recently at the head of various dissolving pulp
companies.
With Fortress, Vinall says he spends half his time focused on
strategy and growth, and the other half on running the Thurso
mill. The cool thing about this job is that here, I get a chance
to do the things Im best at.
He still monitors mill processes from the dashboard on his
computer, and sometimes goes out on the floor to solve prob-
lems. While the mill is still ramping up production, hes sitting
in on daily quality meetings.
Theres not a lot of formal structure here. I believe managers
should do what theyre good at. You work on functions where
you add the most value.
In January, one month after start-up, the mill was averaging
about 350 tonnes/day. Its capacity is expected to be 575 tonnes/
day. Pulp coming off the machine measures about 96% alpha-
cellulose content, somewhat higher than necessary for viscose-
grade dissolving pulp. In fact, the high quality of the pulp has
allowed Fortress to consider targeting some of its output to the
more specialized markets for dissolving pulp.
Vinall says there are opportunities to move up the value chain
in cellulose, to acetate, MCCs, and ethers eventually. With the
fibres we have here, and the process, we could make some of
those other products. But it will probably be a full year before
we do so.
In the meantime, Fortress Paper has plans to re-open and
convert another mill to dissolving pulp, at the former Domtar
Lebel-sur-Quevillon mill in northern Quebec. After success-
fully managing one turnaround, Fortress is going to continue
doing what its good at. PPC
11
 COVER STORY

Made-in-Canada
Nanotech
Canadian research and Canadian engineering have resulted in the first
industrial-scale plant to produce nanocrystalline cellulose. Now, the
small but mighty additive is being tested in various end-products.
By Cindy Macdonald, Editor

W
here is the worlds largest
stockpile of nanocrystalline
cellulose? In Windsor, Que.,
where CelluForce is the worlds only
industrial-scale producer of this tiny
powerhouse.
CelluForce, a joint venture between
Domtar Corporation and FPInnova-
tions, has launched a new specialty
chemical additive onto the world stage.
Production began in December 2011 at
the one-of-a-kind, $36-million facility.
It will scale up to a rate of 1000 kg of
nanocrystalline cellulose (NCC) per day
by the end of this year. Thats 1000 kg
of a material whose average dimensions
are 100 nanometres by 5 nanometres. A
nanometer is one billionth of a metre.
To put that in perspective, a National
Geographic article states that the com-
parative size of a nanometer to a meter is
the same as that of a marble to the size
of the earth.
Accelerated development
It took only two years to bring Cel-
luForce from drawing board to reality.
Scientists at FPInnovations provided the
technical expertise. Dr. Richard Berry
and associates were responsible for the
early research into NCC, its production
techniques, and its potential end uses.
Noram Engineering then translated
that knowledge to a marketable pro-
cess. Domtar recognized the potential of
NCC and came on board as a partner.
The production facility, adjacent to
Domtars Windsor, Que., pulp and paper
mill, came together on time and on
budget. It was designed and engineered
by Noram, and incorporates some of
Norams own proprietary equipment.
The technical innovations embodied
in the plant have been instrumental in
propelling Canada to the forefront of
NCC development.
This is a small product with grand
ambitions, said Domtars president

12 PULP & PAPER CANADA March/April 2012 pulpandpapercanada.com


Photo courtesy of CelluForce
CelluForce has an in-house lab for
process monitoring and product testing.
and CEO, John D. Williams, at the
CelluForce opening ceremony in Janu-
ary. Domtars goal is to maximize the
value of the fibre in our product.
Jean Moreau, president of
CelluForce, says the company is on the
verge of creating a new, significant mar-
ket. Better yet, it will be a high-value
market. NCC is expected to compete with
products like carbon nanotubes, which
can sell for as much as $100/kg. Moreau
notes that NCC must avoid becoming
a commodity filler, because it could not
compete in commodity markets. It needs
to either be used for its strength charac-
teristics or its optical properties.
pulpandpapercanada.com March/April 2012 PULP & PAPER CANADA
Potential uses for NCC
Iridescent or magnetic films
Pigments, inks and cosmetics
Manufacturing of improved construction products
Interior and structural components for the transportation industry
Innovative coatings and new fillers for papermaking
Innovative bioplastics
Reinforced composites
Films for optical switching
Biocomposites for bone replacement
Paint additives
Electrically conductive membranes
Electronic paper printers
Encapsulated quantum dots for crystalline semiconductors
Intelligent packaging materials
Alone, in the lead
For now and the foreseeable future,
CelluForce is the only producer of NCC.
Another research-based organization in
Sweden, Innventia, began production
last year of a product called microfibril-
lated nanocellulose, but Moreau says
that product is produced by a mechani-
cal process, whereas NCC production
involves a chemical reaction.
Closer to home, Alberta Innovates
has declared its intention to produce
NCC, but has revealed few details about
the timeline or the process.
So Moreau concludes that CelluForce
has about a three-year headstart on any
other producer of NCC, in terms of
technology development and markets.
The companys business development
team is exploring opportunities for NCC
around the world. Describing their job,
Moreau says, You need to be resilient,
adaptive, creative, patient, and resilient
again.
Trials integrating NCC into the
manufacturing process of different prod-
ucts are currently taking place with 15
companies in four main sectors: paint
and coatings, films and barriers, textiles,
and composites.
NCC fibre is going to transform us.
It will let us break into new industries,
COVER STORY
said FPInnovations Pierre Lapointe at
the CelluForce ceremony. We are very
proud that this innovation developed by
FPInnovations research team is now
moving from the laboratories to the mar-
ketplace. This is a great day for FPInno-
vations staff and all our partners.
A bio-based chemical in the
making
NCC is an advanced material derived
from wood fibre. It can improve strength,
durability, and toughness of products.
It also has the ability to reduce damage
from wear, abrasion, and light. Its optical
properties allow it to be incorporated into
structures to make light reflective struc-
tures, tunable from ultraviolet to infrared.
(See Potential uses for NCC, above.).
Vancouver-based Noram Engineer-
ing was responsible for transitioning
NCC from the lab to industrial-scale
production. We worked with FPIn-
novations researchers to enhance the
process for commercial production, and
then we were awarded the contract for
detailed process and mechanical engi-
neering of the Windsor plant, says Jim
Wearing, president of Noram.
The $36-million plant was completed
in about 14 months. It is almost entirely
funded by the federal and provincial
13
 COVER STORY
Jean Moreau, CelluForce CEO, at the NCC conversion
unit on opening day.
governments. The Harper Conserva-
tives contributed $23.2 million via the
Pulp and Paper Green Transformation
Program ($12 million of Domtars cred-
its) and through the Transformative
Technologies program administered by
FPInnovations ($11.2 million). Que-
becs Natural Resources and Wildlife
Department kicked in $10.2 million.
All of the processes used to produce
NCC are quite innovative, and unique in
the pulp and paper sector, says Wear-
ing. Noram drew inspiration from pro-
cesses used in the chemical sector and in
production of sulphuric acid.
ad_layout03_noram 12-02-28 1:51 PM Page 1
Engineering &
Constructors Ltd.
14 PULP & PAPER CANADA March/April 2012 pulpandpapercanada.com
This is the acid recovery area at CelluForce.
The NCC production process begins
with dry pulp. CelluForces Moreau
notes that it could be either softwood
or hardwood, or potentially any other
cellulose (with some process modifica-
tions). The pulp preparation process is
confidential, but Moreau does reveal
that the prepared pulp then undergoes
a reaction with acid in two reactors, in
batches. From there, the solution goes
through a continuous flow of various
filtration steps, down to the nano level,
with the solution becoming progres-
sively less acidic. By the final stage
of filtration, the cellulose product is
Engineers and Equipment Suppliers to CelluForce
Congratulations
to CelluForce
on an exceptional project
www.noram-eng.com
Photo courtesy of CelluForce
suspended in water. The solution is
then sprayed into a large heated dryer,
where it becomes a dry powder form
of microcrystalline cellulose, similar in
appearance to talc. The customer will
later re-disperse the microcrystalline
cellulose in a matrix to achieve nano-
crystalline cellulose.
This is only the beginning of the
story, says Moreau. With production
underway and material being shipped
for product trials, we are exactly where
we expected to be. Its an exhilarating
place to be, on the leading edge of the
bio-chemicals market. PPC
pulp_paper_mountains.indd 1 3/15/12 12:08 PM

Creating business
The new opportunities for companies
colour who see things differently.

of colour The result of many years of research, nanocrystalline

cellulose is a nanomaterial extracted from wood fibres.
It can be made into films that are flexible, strong and
easy to handle, varnishes, paints, improved plastics,
biodegradable food packaging and many more new
Security papers Iridescent pigments and innovative products.
Switchable optical filters and barriers Sunscreens
Cosmetics Packaging Coatings

Abundant Renewable Recyclable Environmentally friendly

Discover colour to the power of nano www.fpinnovations.ca

 PAPERWEEK CANADA
Best of Both Worlds
at PaperWeek
Traditional pulp and paper operations and emerging technologies shared the agenda at PaperWeek
Canada, the Canadian industrys week-long learning and networking event.
T
here was universal agreement among the speakers at
PaperWeek Canada that the pulp and paper industry
should move forward with a combination of traditional
pulp and paper products and forays into the bioeconomy.
Attendees at the week-long event could choose between busi-
ness or technical topics, and between sessions on biorefining
or traditional pulp and paper manufacturing. Organized by the
Pulp and Paper Technical Association of Canada (PAPTAC),
PaperWeek Canada also included a seminar on paper machine
optimization, and a gathering for mill managers.
The business track was well attended and provided a forum to
present and discuss strategies being developed to steer the trans-
formation of the industry.
Natural Resources Minister Joe Oliver, in his keynote speech,
said, We all agree that he way forward is a combination of tradi-
tional and innovative technologies. There was remarkable agree-
ment on that sentiment during PaperWeek Canada, from various
representatives of FPInnovations, from Natural Resources Canada
personnel, and from the Forest Products Association of Canada.
The pairing of old and new technologies is also the direction of
much of the research at cole Polytechnique and other universi-
Greg Hay and Dennis Castonguay of Verso Paper,
Bucksport, ME.
16 PULP & PAPER CANADA March/April 2012 pulpandpapercanada.com
By Cindy Macdonald, Editor
ties involved in the FIBRE research network. A similar message
was heard touching on the value chain and economics of adding
biorefining to the existing industry, and developing new wood-
based products.
The 98th annual gathering of Canadas pulp and paper indus-
try was a success, with more than 600 in attendance. The event
was held at the Fairmont Queen Elizabeth hotel in Montreal,
from Jan. 30 to Feb. 3.
The Second International Forest Biorefinery Symposium
was held concurrently with the technical sessions and received
great interest. The biorefinery symposium was again organized
by Mariya Marinova and Jean Paris of Ecole Polytechnique.
In addition, CRIBIQ, a Quebec-based biotechnology research
consortium, hosted a symposium on Jan. 30 on the subject of
forest-based chemicals.
One of the great successes of the event continues to be the
PaperWeek luncheons, which were all filled to capacity.
To stay abreast of plans for PaperWeek Canada 2013, check in
at www.paperweekcanada.ca and www.twitter.com/paperweek-
canada. Next years event will again be held in Montreal, at the
Fairmont Queen Elizabeth Hotel, the week of Feb. 4.
For the hands-on type of people, a paper machine optimization
seminar was offered in the later part of the week.

StrategicpartnershipsMajorThemeinBiorefinerySymposium
PaperWeeks Biorefinery Symposium
opened with a keynote address from Lorne
Morrow, CEO of CRIBE (Center for Research
and Innovation in the Bio-Economy).
Morrow described CRIBEs marquee
demo project, a kraft pulp mill with a fully
integrated lignin extraction process and
laboratory on site. The lignin pilot plant
is operated in partnership with Resolute
Forest Products (Thunder Bay mill) and
FPInnovations.
Morrow identified the importance of
strategic partnerships, with government,
industry players, and academics, in the
success of biorefining projects, echoing
a consensus at PaperWeek this year. He
warned that change is needed, and that
resistance to change in the industry
remains a considerable challenge.
Morrow also asked, what, and where,
is our four percent?, a reference to the oil
industrys oft-cited model, where 42% of
revenue is derived from chemicals, plastics
and rubber, which represents only 4% of
the industrys production.
Morrow concluded that the CRIBE
demo project is only one step down one
path, that many other opportunities in
the bioeconomy need to be assessed, and
reiterated that the bioeconomy needs to
be supported by a healthy forest industry,
a point made clear earlier in the day by
Andrew Casey of FPAC.
The one step theme, along with the
idea of a bioeconomy needing a healthy
forest industry to support it, was echoed,
with minor variation, in many of the panels
at this years conference.
Dr. Allen had the biorefining crowd
thinking of possible environmental
impacts of their processes.
pulpandpapercanada.com March/April 2012 PULP & PAPER CANADA 17
PAPERWEEK CANADA
One biorefining
Another major issue raised in Morrows expert says European
keynote, strategic partnerships, was bioenergy subsidies are
picked up on by Wednesdays keynote
address, given by Michel Chornet, of
leading completely
CRB Innovations, Inc. Entitled Low the wrong direction
grade residual biomass to biofuels and and do not promote
biochemicals: from R&D to commercial new products.
realization, Chornets talk drove home
the importance of CRBs partnership with that the company never loses sight of its
the University of Sherbrookes Chair in eventual goals.
Cellulosic Ethanol for the companys R&D Reino Pulki (Lakehead University)
phases, which otherwise would be very presented a paper on goal programming as
difficult to handle in-house. a means of modeling biomass procurement,
CRB is engaged in a demo scale project looking at quality and cost goals for four
in Quebecs Eastern Townships region, and mills in the same area. The model was found
is working with a hub and spoke model, to be useful in judging tradeoffs between
where satellite plants partially treat biomass cost and quality in biomass, and illustrated
from smaller, readily available pockets, and that the impact of one mills choices is felt
final processing is done at a central plant. In by the surrounding mills.
part, Chornet claims, this system is designed Also in the VCO panel, Yan Feng
to serve HR needs in smaller plants. (Universit de Laval) presented a model
Again, Chornet noted that there are many for making investment decisions based
pathways to take from biomass through to on government policy and incentives,
end products, and that the market for some and Behreng Mansoornejad discussed the
of those products is vastly different from benefits of building flexibility into new
the local commodities market, requiring biorefinery projects, both at the process
international partnerships, including design and operational level, including
academic, industry and government. product and volume flexibility. Flexibility,
Mansoornejad concluded, has a capital
Models for transformation cost, but is justified because it mitigates
Paul Stuart (Polytechnique de Montral), risk. Paul Stuart noted at the end of the
opened Tuesday afternoons session presentation that the industry has tried,
of the Value Chain Optimization and failed, at biorefining in the past, and
(VCO) panel jokingly, noting that the warned of making the same mistakes.
attendance was quite good, considering
that they were up against a biorefining Even newsprint mills could get
panel across the hall. on board
Virginie Chambost (Envertis) discussed During Wednesdays panels, Jawad
transformational value chains for forest Jeaidi, of Montreals Ecole Polytechnique,
companies, in the context of diversifying
a product portfolio. Chambost noted that A Lesson from Petroleum Refineries
the process of product diversification Petroleum End
End-Uses
Uses Revenues
absolutely needs to be guided by a
transformational business plan, which 15%
works in concert with technology, but is 26% 43%
not driven by it. 42%
Her take-home message was a phased 4%
70%
approach, with three phases: lowering
of operating costs, increased revenues, Transportation Fuels
and finally, improved margins. Chambost Chemicals, Plastics, Rubber
also highlighted the importance of strong Other Fuels and Products
Source: T. Werpy,
2009 BioWorld Conference
partnerships, in this case for securing 27
biomass for long terms. According to Many feel the pulp and paper industry
Chambost, the phased approach mitigates needs to find its own high value
risk, and a strong business plan ensures products, like the oil industrys 4%.
 PAPERWEEK CANADA
presented a stand-out paper entitled
Techno-economic analysis of biorefinery
process options for integrated newsprint mills.
Jeaidi noted that this is an understudied
area, and that conventional newsprint mills
do not have a readily available internal
feedstock for biorefinery. Jeaidi therefore
turned to the phased approach, suggested
by Chambost, and three main pathways
for newsprint mills to adopt biorefining,
including extraction and conversion of
hemicellulose to xylitol as a value-added
product, the production of biocomposite
pellets, and the production of PF resins and
bioethanol using the Organosolv method.
Jeaidi concluded that using a phased
approach to mitigate risk, a newsprint plant
could integrate a biorefining element and
increase profitability.
Johanna Jnsson (Chalmers University)
presented the findings of the absent Karin
Petterson (Chalmers University), who
studied black liquor gasification (BLG).
Jnsson noted that the technology for
large scale BLG is still 10-20 years away, and
that BLG is a better fit for market pulp mills.
The choice of product line would need to
be driven by consideration of government
policy (carbon credit, etc.) and the market
value of oil, she concluded.
Other papers presented during the
Biorefinery Symposium included a study
of biorefinery clusters, by Olumoye Ajao
(cole Polytechnique), which concluded
that a net profit increase when producing
furfural was possible for a cluster of
satellite mills and a central mill, depending
on the distance between mills, and that
the cluster works better for dissolving
pulp mills compared with kraft mills.
Zo Prrin-Levasseur (NRCan) and Pardis
Rofouie (cole Polytechnique de Montral)
presented papers modeling the potential
for integrated biorefineries, focusing on
the production of lignin as a co-product
and biomass gasification, respectively.
Shaun L. Turriff
Quebec leads the way in bio-based
products
Speaking at the CRIBIQ symposium on
forest-sourced renewable chemicals,
FPInnovations Jean Hamel said
Quebec leads the way among Canadian
provinces. The recent opening of the
Domtar/FPInnovations joint venture
18 PULP & PAPER CANADA March/April 2012 pulpandpapercanada.com
CelluForce is an example. CelluForce
is the worlds first producer of
nanocrystalline cellulose.
We have the resources, and we know
how to extract them, said Hamel. The
challenge now is to figure out costs and
markets for the multitude of products
available through biorefining.
Hamel noted that the Quebec
government has been forthcoming
with support for biorefining, as has the
federal government. Mariya Marinova,
of Ecole Polytechnique de Montreal,
told participants the most likely route to
success for a biorefining operation will be
integration with a kraft pulp mill to form a
multi-product revenue generating centre.
This will diversify the product mix and allow
integration of energy and material needs.
The CRIBIQ symposium, attended
by about 125 people, also presented
research and developments on plant-
based renewable chemicals available from
Quebecs forests.
Cindy Macdonald, Editor
Bleaching takes centre stage
Theres still a lot of need for research and
innovation in the so-called traditional
pulp and paper business, said Zhi-Hua
Jiang at the opening of PaperWeeks
technical session on bleaching.
The speakers then went on to show
that there is some fresh thinking being
applied to this sector. Jean Bouchard of
FPInnovations noted that industry practice
is to have no routine assessment of white
water quality in kraft pulp mills, which can
lead to a problem: brightness loss. While
this would usually be solved by adding
more chlorine, Bouchard suggests that
another solution is to assess and adjust
white water quality.
A study of six samples of white water
from Canadian mills demonstrated that
fines in the white water are the major
culprit in brightness loss. The effect of
other dissolved solids in the white water is
minimal. Bouchard concludes that the color
and concentration of the fines can have a
direct negative effect on brightness.
James Goldman of Metso Automation
discussed bleach plant control methods.
He explained that Kappa-factor based
control can keep mills operating in a zone
whereby small additions of ClO2 have a
In Canada, we can
only have cheap
biomass for energy
if have a healthy
primary forest
products sector, says
Tom Browne.
large effect. Most mills, he said, operate
at the shallow end of the delignification
curve, where the process is most stable,
but additional ClO2 has little effect.
Dan Davies of Evonik explained why a
final peroxide stage is effective, and two
ways to incorporate this brightening stage
into a mills bleaching process. He noted
that the use of peroxide can brighten pulp,
and reduce reversion. It is the chemical
differences between chlorine and peroxide
that make it so effective at tackling
reversion, said Davies.
Cindy Macdonald, Editor
Natural Resources Minister
supports industry transformation
Canadas Natural Resources Minister had a
message of support for the pulp and paper
industry. The Honorable Joe Oliver told
PaperWeek attendees the government
is committed to maintaining Canadas
leadership position in a sustainable
economy.
Oliver acknowledged that our industry
has spared no effort to become a next
generation industry. The minister was
proud to note that the forest sector
contributes $22.5 billion to the national
economy, and he noted that forest
products exports, aided by wood products
shipments to Asia, are almost fully
recovered to pre-recession levels.
The Pulp and Paper Green
Transformation Program was a
tremendous shot in the arm for the
industry, and its environmental benefits
will be felt for some time. This is likely
the largest initiative for the forest sector
in Canadian history, said Oliver. As a
result, pulp and paper mills have reduced
their greenhouse gas emissions by more
than 10%, and more than 200 MW of
renewable energy capacity has been
installed.
The federal government is now turning
its support to technological innovation,
 PAPERWEEK CANADA
Natural Resources Minister Joe Oliver
praised the industrys efforts toward
renewal.
with the Investments in Forest Industry
Transformation (IFIT) program and
support for research projects. We
want to see new, viable economic
opportunities in Canadas forest
communities, said Oliver.
Cindy Macdonald, Editor
Lazar praises industry for taking
charge of its future
The transformation was painful, said Avrim
Lazar, but our industry is now finding its
feet in the new reality of the pulp and
paper industry. Lazar has been president
of the Forest Products Association of
Canada for 10 years now, and as he
looked at the audience assembled for
PaperWeek Canadas luncheon on Jan. 31,
he commented that the last few years had
been painful.
Lazar spoke of the human aspects of
the transformation that has gripped our
industry. He noted that while people are
accustomed to change, change is usually
happening within a dynamic equilibrium.
Those shifts from one equilibrium to
another, those are transformations, he
said.
Lazar commended pulp and paper
companies for looking forward during this
tumultuous time, and for transforming
[themselves] in the face of these
challenges, not being transformed.
He also praised the government for
putting its money and influence behind
the new equilibrium, not the old.
Cindy Macdonald, Editor
20 PULP & PAPER CANADA March/April 2012 pulpandpapercanada.com
PAPTAC Awards: Bates Medal presented to Cascades Pelletier
PAPTAC presents a number of awards
during PaperWeek, honoring those
that have served the industry well, and
authors of high-quality technical papers
that contribute to the industry pool of
knowledge.
The association changed the protocol
for its awards this year, presenting most of
the awards during the welcome reception,
to a wider audience than in past years.
The most prestigious honors, the John
S. Bates Memorial Gold Medal, a lifetime
membership, and the Weldon award
for best paper, were presented during a
PaperWeek luncheon.
Dr. Martin P. Pelletier, founder of
Cascades Research Centre, received the
John S. Bates Memorial Gold Medal, in
recognition of his long-term contribution
to science and technology in the pulp and
paper industry.
Dr. Pelletier has spent his career with
Cascades. He founded, and continues to
lead, the companys in-house research lab.
I put my heart into it, he said.
In presenting the award, PAPTAC
chairman Patrice Mangin said, as an
innovative man, Pelletier could do no other
than find an innovative company.
Pelletier is the first francophone to receive
PAPTACs highest honor. I was stunned, said
Pelletier. It is an honor not just for me, but
for my family, and for Cascades.
Dr. Martin Pelletier and his supporters from Cascades.
Pelletier said the research centre he
founded in 1985 is a nursery for young
talent, and provides our mills with young
people who have a Cascades mentality.
The research centre is self-financing,
because of that, said Pelletier, the
researchers had to be thinking about
earning money, so projects had to be
scientifically sound and oriented to the
needs of the mills.
It took five or six years before
we made some money, and Laurent
[Lemaire] had to keep telling me not to
change my mind.
Pulp mills should
consider measuring
white water
quality to minimize
brightness loss,
says Jean Bouchard,
FPInnovations
Pelletier is particularly proud of the
chlorine-free process for de-inking and the
anti-bacterial hand towels developed by
his lab.
A PAPTAC Honorary Life Membership
was bestowed upon Ms. Marie Dumontier,
Deputy Director, Pulp and Paper Green
Transformation Program, Natural
Resources Canada, in recognition of her
 CONNECTING PEOPLE
PAPTACs Technical Communities play an essential role
in exchanging information on a variety of issues related
www.paptac.ca to operation optimization, energy, environment, process
and much more. E-mail discussion groups, on-line forums,
conferences: a wealth of information accessible to all
PAPTAC members.

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or contact Thomas Perichaud at 514.392.6956 or tperichaud@paptac.ca
 PAPERWEEK CANADA
Attendees at PaperWeek Canada were generally upbeat this year, and attendance at
the event grew by almost 200, to a total of 609 for 2012.
extraordinary work and leadership as a
past chairman of PAPTAC (2007-2008).
Enrique Mateos-Espejel, Maryam
Moshkelani, Mohammad Keshtkar and
Jean Paris, cole Polytechnique de
Montral, received the I.H. Weldon Award
for the best paper presented at a PAPTAC
event. Their paper is entitled Sustainability
of the green integrated forest biorefinery: A
question of energy.
Holton Quinn, Alberta Newsprint
Company, received the Douglas Atack
Award for the best mechanical pulping
paper for Mill experience in newsprint
quality prediction at the TMP refiners.
Rob Stephenson of Paradigm
Environmental Technologies, Talat
Mahmood, Allan Elliott, and Brian
OConnor of FPInnovations, Cigdem
Eskicioglu and Mithun Saha of UBC, and
Bob Ericksen of Catalyst Paper shared the
Douglas Jones Environmental Award for
their paper How MicroSludge and anaerobic
digestion or aerobic stabilization of waste
activated sludge can save costs to manage
sludge.
The Energy Conservation Opportunity
Tom Browne says in
10 years, Canada will
have a brownfield
biorefinery producing
cheap-to-ship
intermediates.
22 PULP & PAPER CANADA March/April 2012 pulpandpapercanada.com
Award, presented by Pulp & Paper Canada,
went to Mike Vallee, of Alberta Newsprint
Company, for his paper Energy savings in
broke handling systems at ANC.
The F.G. Robinson Award for exceptional
service by a technical community chairman
was presented to Aqeel Zaidi, Enbridge
Gas Distribution, chairman of the Energy
Community.
Marcius de Oliveira, Alberta Pacific
Forest Industries, received the Howard
Rapson Award for his paper entitled Bleach
Plant Scale and Control - Mill Case Study. At
the time that he developed and presented
the paper, de Oliveira was an employee
of Daishowa Marubeni, Peace River Pulp
Division.
A Certificate of Appreciation was
awarded to Jon LeRoy, Irving Pulp & Paper
for his exceptional service as chairman of
the PAPTAC Atlantic Branch.
Heads up: emerging research
In Wednesdays Emerging Research panel,
Robert Pelton of McMaster University
presented information about microgels. In
his paper, Microgels, a new route for getting
more glue into paper, Pelton concludes that
using polyvinylamine (PVAm) microgels,
rather than simple PVAm polymers,
increases the amount of adhesive in the
paper, resulting in a stronger wet tear
strength.
Pelton demonstrated that the theoretical
model developed at McMaster to test
microgel adhesion compared well to actual
90 degree peel tests. In practical terms,
Pelton suggests that strength enhancing
polymers, such as PVAm, are more effective
when coated on soft nanoparticles, such as
the microgels in his study.
Qiaozhi An, of the University of New
Brunswick, presented a paper on the
potential of thermal-sensitive hydrogels for
use in drug delivery systems, wastewater
management, and high value papers,
including anti-bacterial and anti-viral
papers, thermosensitive paper, and as a
retention aid in papermaking.
Shaun L. Turriff
PaperWeek trade show
The PaperWeek trade show had about
30 exhibitors.
Maxcess offers the Tidland blade
sharpening system, which allows
blades to be sharpened without
removal from the cartridge, and
without being sent out to be reground.
The unit sharpens blades from
Tidlands Performance Series, Series
C swing cartridge, and e-knifeholder
blade cartridges, in 90 seconds.
At the Glenco booth, the iTable
adjustable fourdinier sheet forming
zone was presented. With the iTable
from IBS, the papermaker can control
the drainage and stock activity from
the headbox all the way to the end
of the sheet forming zone. The foil
blade spacing and design achieves
extremely high pulse frequencies
above 150 Hz. This results in very
fine microturbulence for high levels
of shear and fibre mobility during
the sheet forming process. Glenco
reports that 10 paper machines have
been rebuilt with iTable technology
in North America, and three more
rebuilds are in the works for the first
half of 2012.

Working Together for the
Safety of All
The safest mills in Canada share a mindset that goes beyond safety management.
Employees take personal responsibility for ensuring their safety, and that of their team.
C
anadas safest mills put a strong
focus on employees working
together to identify and elimi-
nate potential hazards in the workplace.
The methods vary, but the top performers
all emphasize individual responsibility for
health and safety.
At the Weyerhaeuser pulp mill in
Grande Prairie, Alta., the emphasis is on
personal risk assessment. Weve always
had safe job plans and work orders that
describe the safe way to complete the job,
but now we have every employee and con-
tractor thinking about their personal safety,
both at the job site and before beginning
work, health and safety manager Linda
Perkins Perkins says Personal risk assess-
ment] includes focusing on your mindset as
well, recognizing that we often bring dis-
tractions from home into the work place.
The Grande Prairie mill had zero
recordable safety incidents last year, and
was one of the winners of Pulp & Paper
Canadas Safest Mill in Canada contest
for 2011.
Bryan Lundale, a regional vice-pres-
ident of the Canadian Society of Safety
Engineers, says an organizations corpo-
rate culture is an important determinant
of the incidence of workplace accidents.
The corporate culture must promote
health and safety in a proactive manner
that identifies potential hazards and risks,
and then takes the necessary actions to
prevent any incidents that could arise,
Lundale said. The culture needs to be
one where everyone understands that
safety is their responsibility. The culture
cannot be one that [reacts to] incidents
that have already taken place.
Terry Lee, health, safety and train-
ing coordinator Lake Utopia Paper Ltd.,
says his companys corporate culture puts
safety first.
pulpandpapercanada.com March/April 2012 PULP & PAPER CANADA
SAFETY
By Peter Caulfield
This culture is driven from the top score card is getting action taken and
down and this, I believe, is why we are completed within the allotted time
doing so well, he says. Lake Utopia, a frame, Lee said.
corrugated medium mill in southwestern
New Brunswick that sells paper to card- Scaled-down safety program
board box manufacturers, had a record- Northern Pulp Nova Scotia, located 150
able incident frequency of 1.36 in Pulp kilometres northeast of Halifax, had only
& Paper Canadas 2011 Safest Mill in one reportable injury in 2011, and was the
Canada contest. winner of Category C in the 2011 Safest
Lee says Lake Utopia Paper holds daily Mill in Canada contest.
safety tool box meetings, safety audits, and The companys safety record is worthy
job hazard analysis. In addition, all inci- of note, because it has had three different
dents are addressed and dealt with quickly. owners in the last six years and the mill is
One of the measures on our safety at least 40 years old.
Safest mills: Al-Pac, Weyerhaeuser and
Northern Pulp
Alberta Pacific Forest Industries, Weyerhaeusers Grande Prairie
site, and Northern Pulp Nova Scotia were the safest operations in
Canada last year, according to Pulp & Paper Canadas Safest Mill
in Canada contest. Weyerhaeuser was the only participating mill to
have zero incidents in 2011.
Alberta Pacific Forest Industries placed first among large mills,
with six incidents and a frequency rate of 1.11. Howe Sound Pulp &
Paper placed second at 1.13.
There was a change to the rules this year, to reflect the fact that
fewer mills are reaching the 100,000 man hours per month threshold
for Category A. The threshold value was lowered to 80,000 man
hours per month for 2011. Domtars Windsor mill, which had domi-
nated the small group of Category A mills for several years, fell to
third place with a frequency rate of 1.22.
Category B was won by Weyerhaeusers Grande Prairie mill,
whose employees are to be congratulated for achieving a zero-
incident year. Hinton Pulp (0.94) and Resolute Forest Products Alma
mill (0.99) came in second and third in this category.
Sonoco Canadas Brantford site, which had an unblemished
record for seven years, allowed one incident in 2011, and cedes the
top spot in Category C to Northern Pulp Nova Scotia.
Northern Pulp had one incident in 2011, for a frequency rate of
0.35. Slave Lake Pulp placed second with a frequency rate of 0.92,
and J.D. Irvings Lake Utopia Paper was third with 1.36.
23
 SAFETY

Safety leader Mike Pittoello says North-

ern Pulps corporate culture dates from when Safest Mill in Canada, 2011 Results
it was owned by large multinationals Scott
Paper and Kimberley Clark. Total Total Frequency
We have a good solid foundation from Recordable hours
our early days, but scaled back for a stand- incidents worked
alone business, Pittoello said. CATEGORY A
OVER 80,000 MANHOURS PER MONTH -- Changed for 2011
Northern Pulps safety management sys-
Alberta Pacific Forest Industries Inc., Boyle, AB 6 1078823 1.11
tem has two main elements.
Howe Sound Pulp & Paper Corp., Port Mellon, BC 6 1064843 1.13
The first is to identify hazards and evalu-
Domtar Inc., Windsor, QC 9 1471981 1.22
ate the risk of exposure and take action, Pit- Resolute Forest Products, Fort Frances, ON 8 991768 1.61
toello said. The second is to get employees Resolute Forest Products, Baie-Comeau, QC 11 998251 2.20
to recognize and control hazards at the work- Catalyst Paper, Crofton, BC 33 1090047 6.05
place and beyond, especially at home and on
the road while driving. CATEGORY B
50,000 to 80,000 MANHOURS PER MONTH - Changed for
2011
Alberta-Pacific gets SMART about
Weyerhaeuser Canada, Grande Prairie, AB 0 608430 0.00
safety
Hinton Pulp (Div. Of West Fraser Mills), Hinton, AB 3 640817 0.94
Alberta-Pacific Forest Industries Inc., locat- Resolute Forest Products, Alma, QC 4 811174 0.99
ed in north-central Alberta, is the largest Resolute Forest Products, Kenogami, QC 5 632325 1.58
single-line bleached kraft pulp mill in North Kruger Inc., Bromptonville, QC 6 667555 1.80
America. The operation achieved an inci- Kruger Wayagamack Inc., Trois-Rivires, QC 6 654460 1.83
dent frequency of 1.1 for 2011, taking top Canfor, Northwood Pulp Mill, Prince George, BC 9 945382 1.90
spot among the large mills in the Safest Mill Canfor, Prince George Pulp & Paper, Prince George, BC 7 689148 2.03
contest. Irving Pulp & Paper Ltd., Saint John, NB 9 791880 2.27
Barry Greenfield, health and safety busi- Resolute Forest Products, Thunder Bay, ON 10 862870 2.32
ness unit leader, says Alberta-Pacific imple- Twin Rivers Paper Co., Edmundston, NB 9 756586 2.38
mented the SMART process (Safely Man- Resolute Forest Products, Laurentide, QC 10 776494 2.58
aging Accident Risks Together), the compa- Zellstoff Celgar Limited, Castlegar, BC 12 824313 2.91
nys behavior-based safety program, in 2000. Catalyst Paper, Powell River, BC 12 727128 3.30
Team members are trained as observers to Kruger Inc., Trois-Rivieres, QC 11 635189 3.46
watch co-workers on the job and to identify CATEGORY C
behaviors that could pose a safety risk. Then LESS THAN 50,000 MANHOURS PER MONTH
they work together to reduce accidents by Northern Pulp Nova Scotia Corp., New Glasgow, NS 1 576993 0.35
eliminating the unsafe behaviors. Slave Lake Pulp Corporation, Slave Lake, AB 1 218329 0.92
A focus on safety is built into the companys JD Irving Ltd., Lake Utopia Paper Ltd., St. George, NB 2 294508 1.36
non-traditional management system, which is Strathcona Paper LP, Napanee, ON 2 278364 1.44
based on a self-directed team model. Resolute Forest Products, Amos, QC 3 408855 1.47
The founders believed that the best way Sonoco Canada Corporation, Brantford, ON 1 133379 1.50
to achieve a satisfying and high-performing Resolute Forest Products, Iroquois Falls, ON 5 568701 1.76
workplace where safety, open communication, Resolute Forest Products, Clermont, QC 5 547304 1.83
Bowater Mersey Paper, Liverpool, NS 5 482938 2.07
productivity and quality are always at the fore-
Cariboo Pulp and Paper Co., Quesnel, BC 6 577341 2.08
front was through self-managed work teams,
Meadow Lake Mechanical Pulp Inc., Meadow Lake, SK 4 375398 2.13
Greenfield said.
Quesnel River Pulp, Quesnel, BC 3 270280 2.22
Every employee at Alberta-Pacific is a Millar Western Forest Products, Whitecourt Pulp, Whitecourt, AB 3 241120 2.49
member of a team. Each team is small Alberta Newsprint Company, Whitecourt, AB 6 460947 2.60
between six and 15 people and members Resolute Forest Products, Thorold, ON 5 378516 2.64
are trained to manage their own activities. Catalyst Paper, Port Alberni, BC 11 559911 3.93
Minas Basin Pulp & Power, Hantsport, N.S. 6 303703 3.95
Weyerhaeuser Grande Prairie on a Daishowa Marubeni International, Peace River, AB 11 549614 4.00
safety roll Canfor, Intercontinental Pulp, Prince George, BC 10 488342 4.10
The Weyerhaeuser Grande Prairie oper- Tembec Kapuskasing Operations, Kapuskasing ON. 13 597379 4.35
ations, in northwestern Alberta, had no JD Irving Ltd., Irving Tissue, Saint John, NB 5 228532 4.38
reported incidents in 2011. In fact, says Cascades Groupe Carton Plat East Angus, East Angus, QC 4 177227 4.51
health and safety manager Linda Perkins, Tolko Manitoba Kraft Papers, The Pas, MB 15 554796 5.41
the site has had a recordable incident rate of Kruger Inc., Montreal, QC 9 280700 6.41
less than 1.0 for the past five years. Norampac Inc., Trenton, ON 9 243408 7.39

24 PULP & PAPER CANADA March/April 2012 pulpandpapercanada.com

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 SAFETY
Safe production is the only accept-
able production, Perkins comments.
Safety is not owned by the healthy and
safety department. Its owned by every
person who works on the site. Lead-
ers are expected to manage the safety
of themselves, their employees and the
work they perform. The health and safety
department provides technical support
and expertise.
Perkins says that for the past few years
the company has focused on personal risk
assessment before starting a task. In 2012,
the operations safety focus is on helping
employees perceive risk.
Each of us has a different perspective
and tolerance based on personal experi-
ence, she said. We are using concepts
from some hazard recognition training we
recently received to help us perceive all risks
that are present. If we see it, we can solve it.
Older workers have different
needs
Jerry Traer, a program training special-
ist with Workplace Safety North, which
provides occupational health and safe-
ty resources, training and consulting to
companies in Ontario, says he has been
TECHNOLOGY NEWS - REFINING
Stickies removal and screen cylinders:
Research published
Kadant recently issued its latest technical
white paper, Ministickies Removal and 4th
Generation Screen Cylinders. The paper
presents the screening capabilities of fourth
generation cylinders offered by major
equipment suppliers and evaluated their
performance, including the FibreWall
screen cylinder from Kadant. Initial field
results of the FibreWall cylinders are
promising and suggest that the generally
accepted screening limits can now be
extended to smaller stickies in Classes 1 to 4.
The technical white paper is available free
for download at http://www.kadant.com/
26 PULP & PAPER CANADA March/April 2012 pulpandpapercanada.com
seeing more muscular-skeletal disorders
in the pulp and paper industry lately.
There are more older workers in the
industry today, because of mill closures and
cut-backs, Traer said. When the industry
was booming, there were more 25-year-
olds employed. When they injured them-
selves, they were out for a day or two and
then they were back on the job. But these
days the average age of pulp and paper
workers is 52-53. When they get injured,
theyre off the job for longer.
On the positive side, the consolidation
taking place in the industry means that
many small operations are being taken
over by bigger companies which have the
money and expertise to place a greater
emphasis on health and safety.
Big companies take more of a long-
term approach, including how they han-
dle work place safety, Traer says.
Safety management is not
enough
Jeffery Lyth, a Vancouver-based safety
expert who is principal of QSP Leadership,
says most businesses have sought to achieve
safety as an outcome by applying and
administering safety management systems.
fibrewall. For additional information, please
contact Daniel Parenteau at dparenteau@
kadantbc.com or call 1-866-419-6442,
ext. 103.
Kadant Black Clawson, 877-369-6111,
www.kadant.com
BCTMP art paper line consumes
minimal energy
Metso delivered last year a complete,
state-of-the-art pulp manufacturing
line for high-quality coated paper at
Shouguang Meilun Paper Co., Ltd., of
China.
The pulp line, with a production capacity
of 500 tons/day, uses mainly poplar and
eucalyptus from the mills own plantation
and from nearby suppliers.
The new Metso BCTMP line (bleached
chemi-thermomechanical pulp) consists of
the RGP 82 CD refiner followed by a two-
stage bleaching and final refining carried
out in conical OptiFiner refiners. According
to Metso, the Meilun BCTMP line produces
the most energy effective pulp in the
While this approach is necessary in
order to show due diligence, and while
it is somewhat effective, many business-
es are realizing it has limited return
on investment on its own, states Lyth.
They find themselves engaged in many
activities which are necessary but insuf-
ficient for attaining their goals.
Most businesses have sought to solve
their safety problem by creating a safety
culture.
Culture plays a critical role in an effec-
tive and integrated operational system, but
many [company executives] are at a loss
when tasked with going out and creating it
in their organization, Lyth notes.
In order to create an effective safety
culture, Lyth says businesses must be
prepared to question long held beliefs and
challenge their existing mental models.
They must be prepared to inspire and
engage the hearts and minds of the work
force in order to achieve [an effective
safety] culture, he explains. Most impor-
tantly, companies must help their supervi-
sors and foremen to understand their roles,
and to learn to use new [communication]
tools with which to practice their new
trade, which is leadership. PPC
world. Bleaching in two stages also reduces
chemical consumption when targeting high
pulp brightness.
We are very pleased with the new
pulp line. Its energy-efficient, easy to
run, effective, and very flexible. We can
maneuver the line to switch from one
quality to another in a few minutes, for
instance, from art paper to newsprint
quality. It makes our mill very cost-effective
and enhances our productivity significantly,
says the production manager at the mill.
Metsos RGP 82 CD refiner is a single disc
cantilever design with hydraulic positioning
of the rotor disc and the front cover
supporting the non-rotating stator disc.
A flat inner refining zone and a conical
shaped outer zone make the CD concept
unique. The hydraulic system, operated by
a guide valve, controls the disc clearance on
the conical zone and an electric motor with a
worm gear operates eight transroll screws for
control of the disc clearance on the flat zone.
Metso Paper Ltd. 514-335-5426,
www.metso.com

Shaft ensures maximum up-time
The new Tidland G890 External Element
Shaft from Maxcess combines ease of
maintenance with full global support for
parts and service.
The shaft features a proven air system
design that insures maximum up-time
while being easy to maintain. The
expanding elements ensure superior
torque for consistent and predictable
wound roll tension.
The G890 External Element Shaft
represents the combined innovation
of our European and North American
design teams with a rigorous focus on
standardization, said Sean Craig, global
product manager for Tidland Winding.
Our customers serve a global market and
we are pleased to release an entire suite
of winding products with innovative and
standardized features and components
that are supported literally around the
world.
Maxcess International 405-755-1600,
www.maxcessintl.com
KapStone chooses MAJIQ
manufacturing execution systems
KapStone Paper and Packaging has
selected MAJIQ to deliver a number of
projects during 2012. MAJIQ is extending
the footprint of its Elixir product at
the Roanoke Rapids Mill, installing a
manufacturing execution system (MES)
into the Cowpens mill, and moving sales
order processing (SOP) functions to a
centralized HQ Elixir system.
This series of projects furthers our
objective of operating our production
business on standard software that fits
the way we go about delivering product
to our customers, says Christophe
Deslandes, vice-president and CIO of
KapStone. The outcome of this initiative
will help ensure that KapStone is well
positioned for the future and will deliver
even better service and value to our
customers.
pulpandpapercanada.com March/April 2012 PULP & PAPER CANADA
Steve Latham, president of MAJIQ,
adds, KapStone will have a state-of-
the-art order to cash backbone which
will allow them to be agile and provide
their customers with timely and accurate
information.
Headquartered in Northbrook, IL,
KapStone Paper and Packaging produces
unbleached kraft paper products,
linerboard and shipping containers.
MAJIQs Elixir product provides
integrated sales order processing (SOP) and
manufacturing execution systems (MES).
MAJIQ Inc. 604-886-2538,
www.majiq.com
Foam forming has potential to reduce
raw material and production costs
VTT Technical Research Centre of Finland,
together with industry, is setting up a new
pilot scale technology platform for foam
forming applications.
According to VTT, foam forming
technology makes it possible to improve
paper properties and manufacture
high porosity, smooth and light weight
products (e.g. hygiene products, insulation
materials, and filters). It may be a solution
for various printed intelligent, nano- or
microcellulose applications.
The foam forming technology requires
significantly less water than conventional
paper and board manufacturing. In
foam forming, large amounts of air are
mixed into the fibre furnish which makes
it possible to achieve unique product
properties, states VTTs technology
manager Janne Poranen. This technology
reduces water and energy consumption
while saving raw material. Laboratory
results from the Forestcluster programmes
have shown potential for remarkable fibre
savings.
Other partners of the project are UPM,
Stora-Enso, M-real, Metso, Kemira, Omya,
Wetend Technologies and Vision Systems,
and the cities of Jyvskyl, nekoski and
Jms.
VTT Technical Resarch Centre of Finland
358 20 722 111, www.vtt.fi
Stora Enso orders a compact approach
flow system
POM Technology Oy Ab has received
an order for the supply of a compact
approach flow system for Stora Ensos
TECHNOLOGY NEWS
new testliner machine in Ostroleka Mill in
Poland. The start-up is scheduled for the
first quarter of 2013.
At a wire width of 8,600 mm and a
design speed of 1,800 m/min, the new
Narew PM5 project will produce 455,000
metric tons of testliner per year.
The POM compact approach system
delivery includes: two POMix Stock
Processors for efficient stock mixing, three
POMp Degassers for white water dearation,
two POMlock suction leg sealing units as
well as compact process solutions and
engineering for the whole approach flow
system.
Stora Ensos focus of this investment
was on operational savings from improved
drainage, cleanliness and quality as well
as on space and especially energy cost
savings, which all are met by POM System
applications and principles.
POM Technology became part of Aikawa
Fiber Technologies (AFT) at beginning of
2012.
Aikawa Fiber Technologies 514-481-
6111, www.aikawagroup.com
Wastewater measurement technology
reduces chemical costs
Metso has developed an online
measurement technology with which
municipal and industrial wastewater plants
are able to improve their performance and
reduce the amount of chemicals used in
the sludge drying process by even up to
one-third.
The new Metso Low Solids
Measurement is the first online
measurement technology for municipal
and industrial wastewater treatment
plants that enables measurement of
a media with very low solids contents
in difficult applications, like centrifuge
centrate. The technology also offers
significant savings per centrifuge in
polymer and centrifuge usage.
According to Metso, one large North
American wastewater treatment plant
27
 TECHNOLOGY NEWS
has calculated savings of up to 30% of its
chemical costs. In addition, a municipal
plant in Finland using Metso LS
estimates that they will achieve annually
EUR 15,000 savings in polymer and
centrifuge usage only by keeping reject
water total suspended solids lower that
1000mg/l, says Timo Rantala, product
manager, Metsos Automation business
line.
The Metso Low Solids Measurement
system is based on LED and laser
technology. It dearates, filters, and
measures the process solids. It also has
self-cleaning capabilities to keep the
measurement optics clean for continued
accurate measurement.
With Metso LS measurement it is
possible to control polymer usage and
thus improve throughput and function
of the centrifuge. A higher solids content
of concentrated sludge results in higher
thermal energy in the subsequent
incineration process, or alternatively
reduces transportation costs when
shipping to a landfill. Furthermore,
Metso LS reduces conventional sampling
and laboratory work due to its reliable
and accurate operation.
Metso Automation 514-908-7045,
www.metso.com
Automation upgrade will diversify
paper grades
ABB recently won an extensive order to
upgrade automation at DS Smith Paper
Ltd.s Kemsley Mill in Sittingbourne, Kent,
England. The new systems will help the
28 PULP & PAPER CANADA March/April 2012 pulpandpapercanada.com
mill produce a greater diversity of high
quality paper products.
The order includes an upgrade of the
mills PM3 automation and drive systems.
The mills Advant QCS will be upgraded
to an 800xA with two new network
platforms and an air water spray. The
drives upgrade includes new ACS800
drives and AC800M controllers. One of the
existing DCS Advant controllers will be
upgraded to an AC800M and integrated
into the system.
The upgraded ABB drives will deliver
fast start ups and benefits over the
equipment lifecycle that include increased
productivity, improved quality and energy
savings, while the new web imaging
solution will give the mill a state-of-the-
art tool for identifying web defects and
managing visual uniformity.
The Kemsley Mill is rebuilding PM3 to
produce high quality linerboard and white-
top liner grades. The new systems will be
ready for start-up in June 2012.
ABB, www.abb.com
Honeywell system selected for quality
control of recycled newsprint
Honeywell has been selected by
Kahramanmara Kat Sanayi ve Ticaret
A.., (KMKPAPER) to deploy its Experion
MX Quality Control System (QCS) and
Experion Process Knowledge Control
System (PKS) at a new paper mill based in
Ktahya, Turkey.
The facility, which is due to be
completed in May 2012, will produce
de-inked newsprint, as well as printing
and writing paper. The Experion MX QCS
will be used to monitor consistent paper
quality using constant measurement
of all critical variables to meet the high
standards demanded by the customers.
Honeywells Experion systems help
Kahramanmara Paper produce high
quality paper grades using only recycled
stock without the need to add virgin pulp.
The integrated control system also allows
the pulping and papermaking processes to
operate at maximum efficiency, optimizing
energy and raw material usage.
This will allow them to produce high
value-added paper grades with recycled
pulp using less energy and raw materials
and positioning this new facility to be
more efficient and profitable, said Orhan
Genis, vice-president sales, EMEA, for
Honeywell Process Solutions.
Honeywell Process Solutions,
www.honeywellprocess.com
Lower torque gear drives
SEW-Eurodrive has rounded off the lower
power range of the robust X-Series helical
and bevel-helical gear units by offering
gear units for the torque range of 6.8 to 45
kNm (5000 to 33,000 ft-lb).
The X Series finely graduated size and
high power density results in savings
in terms of both weight and cost. The
large amount of pre-defined accessory
equipment creates flexibility in terms
of adjusting the unit to each respective
application.
SEW-Eurodrive Co. of Canada Ltd.
905-791-1553, www.sew-eurodrive.com
Yankee cylinder drive unit reduces
life-cycle costs
Moventas Santasalo has developed a
new gear series of Yankee cylinder drive
units with enhanced layout designed to
meet the needs of todays high-speed
tissue machines. Its cost-effective and
maintenance-friendly structure is said
to reduce the life-cycle costs of Yankee
cylinder drive units.
The unique pre-load arrangement of the
main bearing is a completely new design
that Moventas Santasalo has developed to
optimize load distribution. This stabilizes
the running of the Yankee cylinder drive
unit and consequently extends bearing life.
Additionally, the pre-load arrangement of
the main bearings is adjustable, for instance,
in situations when a unit is used as a
spare reducer for opposite-handed tissue
machines.
Moventas Santasalo Oy, 358 20 184
7100, www.moventas.com
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Freeman Staffing, Inc. specializes in the placement of engineers
(all disciplines), production type supervisors, managers, mill and/or
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pulpandpapercanada.com March/April 2012 PULP & PAPER CANADA 29

 OPINION
Silver Lining to Fine Papers Decline
S A Snapshot of Canadas Fine Paper Industry
tatistics on the paper industry in
Canada are startling enough to
give anyone pause. Stories abound
of closed mills, company exits and lay-
offs. In just the last year alone, the paper
industry has shrunk dramatically. This
year is likely to be more of the same, with
82% of forest sector CEOs planning to
cut costs in 2012, according to PwCs
15th Annual Global CEO Survey.
It can be argued that the paper indus-
try of today is in worse shape than the
automobile industry of the 1980s, with
operating mills, paper prices and produc-
tion volumes all in decline.
Paper cuts
We have all heard these anecdotes of
our industrys cuts. We hear about cuts
to inventory, costs, jobs and plants. It is
a natural reaction to the digital revolu-
tion that is shrinking our industry.
But dont write off our industry yet.
Its not vanishing; its just evolving. New
realities dont mark the end of an indus-
try, but rather a harsh message that it is
time to reinvent ourselves.
The key to Canadas future success in
the paper industry can be boiled down
to one word: investment. Right now,
there are mills in Asia and Europe that
are so advanced that that they look more
like science fiction movies than paper
facilities. One week of output from some
overseas mills can equal a full year of
production capacity for a Canadian fine
paper mill. These high-technology opera-
tions make better paper products, more
quickly, at a lower cost. Canada wont be
able to compete with these world-class,
state-of-the-art manufacturing facilities
by working with the same old equipment
in the same old way.
Invest and evolve
The paper industry is in a state of evolu-
tion, and Canada needs to be a part of
30 PULP & PAPER CANADA March/April 2012 pulpandpapercanada.com
By Glenn Clifford, APP Canada
Canada 1980s
13 paper merchants
30 to 40 fine paper mills
Paper selling for $1.50 a pound
30% foreign distributorship
Globally competitive labour market
Print-driven economy
Canadian dollar at an all-time low in
2002, Canadian products become cheaper
to buy
it. But the fact is, Canadian investment
in our industry is severely lacking. As an
example, our country has not had a new
fine paper manufacturing machine in 25
years! Todays lower demand for tradi-
tional paper products makes it the oppor-
tune time to reinvest in converting mills
to produce pulp and paper products that
are on the cusp of their demand. Now is
our chance to switch gears and become
the new pulp and paper industry. It is the
oldest adage in the world the Canadian
paper industry must evolve to survive.
How do we know where industry
demand will be in the future? We dont
have a crystal ball, but an agile company
can, in a general way, see which way the
paper industry is pointing. We know that
shorter digital press runs will continue to
be the norm, wide format runs will be
more popular, hybrid packaging that
combines product and shipping packag-
ing will be in high demand, innovations
in food packaging will always garner
attention, and people wont suddenly
stop using napkins and tissue paper.
Canada 2012
Four paper merchants
A handful of fine paper mills left
Paper selling for between $0.50 and
$0.55 a pound
More than 50% foreign
distributorship
Less globally competitive work
environment with rising hydro rates,
labour costs, and a stronger dollar
Move to digital platforms decreasing
demand for printed products
Canadian dollar climbs in value
for a decade, limiting cross-border
advantage
We are also just starting to realize
that pulp manufacturers have other
options besides creating paper, like
Fortress Paper, who has repurposed
its specialty pulp for use in the textile
industries.
APP Canada is another example of
a company that has realized the need to
reinvent its business model to capitalize
on changing times. APP isnt raising
any white flags. Instead, we are expand-
ing our paper merchant product offer-
ings, doubling our staff, increasing our
national presence and getting ready for
the next wave of growth that will turn
our old industry into a new one.
Canada has what it takes to reinvent
our industry. I am hopeful that our abil-
ity to adapt to the digital age will lead
to the birth of an entirely new pulp and
paper industry in Canada.
Glenn Clifford is a paper industry veteran, with
25 years of experience in the paper industry.
He currently leads sales for APPs Canadian
operations.
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