Case Study: Improving Papermaking Efficiency with Polyacrylamide

Background

In Latin America, packaging paper producers play a vital role in supporting the regional food, logistics, and manufacturing industries.
Many paper mills in the region rely heavily on recycled OCC pulp, which brings both cost advantages and technical challenges.

A packaging paper mill located in Latin America contacted Bluwat seeking to improve production efficiency while reducing raw material loss and water consumption.

The mill was facing the following issues:

• High loss of fine fibers and fillers in the wet-end system

• Fluctuating drainage and unstable sheet formation

• High turbidity in White Water, limiting internal reuse

• Increasing pressure to reduce freshwater usage and wastewater discharge

Initial Operating Conditions

• Raw material: Recycled OCC pulp

• Paper grades: Testliner & Fluting

• Basis weight: 110–180 g/m²

• Wet-end pH: Neutral to slightly alkaline

• Water system: Semi-closed loop with limited White Water reuse

Bluwat Polyacrylamide Solution

After laboratory testing and on-site trials, Bluwat proposed a tailored Polyacrylamide program, focusing on three key objectives:

1. Improve retention of fibers and fillers

2. Enhance paper strength performance

3. Clarify White Water for reuse

Products Selected:

• Blufloc C8020 / C8030– Cationic Polyacrylamide (Retention & Drainage Aid)

• Blufloc AA5412– Anionic Polyacrylamide (Dry Strength Agent)

• Blufloc AA5516 – High Molecular Weight Anionic Polyacrylamide (White Water Clarification)

1. Wet-End Retention Improvement

Product: Blufloc C8020 / C8030

Blufloc C8020 and C8030 were applied at the fan pump / headbox section to enhance the retention of fine fibers and fillers.

Results Observed:

• Filler retention increased from around 55–60% to 80–85%

• Noticeable reduction in solids content of white water

• More stable drainage and reduced vacuum load

• Improved sheet formation and surface uniformity

This significantly reduced raw material losses and improved paper machine stability.

2. Paper Strength Enhancement

Product: Blufloc AA5412

To meet strength requirements for packaging grades, Blufloc AA5412 was introduced as a dry strength additive.

Performance Improvements:

• Increased tensile and burst strength

• Better folding endurance, especially for fluting paper

• Improved fiber bonding and paper structure consistency

The mill was able to maintain target strength properties while optimizing fiber usage.

3. White Water Clarification and Reuse

Product: Blufloc AA5516

High turbidity in white water previously limited reuse within the system.
Blufloc AA5516 was applied in the white water clarification process, working synergistically with existing inorganic coagulants.

Treatment Results:

• White water changed from turbid to visibly clear

• Suspended solids reduced to below 50 mg/L under optimized conditions

• Clarified water reused in the papermaking process

This helped the mill reduce freshwater intake and stabilize wet-end chemistry.

Overall Results Achieved

After implementing the Bluwat polyacrylamide solution, the Latin American mill achieved:

✔ Higher retention of fibers and fillers
✔ Improved paper strength and quality stability
✔ Effective white water reuse
✔ Reduced freshwater consumption and wastewater discharge
✔ Lower overall production and operating costs

Conclusion

This Latin America case demonstrates how polyacrylamide plays a critical role in modern papermaking, especially in recycled pulp-based packaging paper production.

By applying the right PAM products at the right process stages, paper mills can significantly improve efficiency, sustainability, and profitability without major equipment investment.