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In 2019, Norwegian corrugated packaging manufacturer Glomma Papp first tested Exilva, a natural glue additive manufactured by Borregaard. The plant soon phased out boron entirely and was making millions by reducing steam consumption and increasing corrugator productivity
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“Since April 2019, we have used a combination of Exilva and boron,” says Jan Berg, Corrugator Supervisor at Glomma Papp (Norway). “We feel that we have found a glue that works very well, by using Exilva as an additive.
“Better production, especially on difficult grades. Here we have seen a 25-30% increase in speed. One glue recipe only that we run at both stations, both single facer and double backer.
“We also continue to reduce glue consumption and glue gaps. In many cases, we have been down to what mechanically and technically possible to run, i.e. a minimal glue gap on the machine.
“Through 2019, we have run 100% boron-free on several qualities. For the few qualities we did not get 100% as wanted, we have had a combination of Exilva and boron as a backup.
“But I saw opportunities to develop the adhesive recipes further, and in September 2019 we did another test recipe without boron.
“So far it looks very positive, so I am very hopeful about the future of Exilva as a replacement for boron products (since 2021, the company completely refused of boron).
“Exilva enables us to run smoother, faster, and with improved quality and speed. Based on around 70 million sqm of boards produced with Exilva, we’ve measured production improvements by 14% and reduced warp by 11%.”
“Currently, production is much more stable,” Jan’s colleague adds. “The adhesive glues much better and boards are flatter. I can rely on the glue much more than I did before. I can rest more knowing that it is stable.
“Before Exilva, I had to check more often and was afraid that it wouldn’t glue enough, but now it does.”
“I can recommend the combo of Exilva and boron to anyone who has problems of any kind when it comes to gluing and warp,” Jan Berg concludes. “Because I think Exilva can help solve those problems. For real.”
Exilva is a fully natural and sustainable multifunctional wood-based solution, developed by Borregaard by microfibrillating the cellulose.
The product has a unique combination of robustness and rheological properties creating a strong network that enables the replacement of boron derivatives in corrugated starch glue systems.
Exilva has the ability to stabilise starch adhesives, both physically and chemically by means of an entangled network of cellulose fibrils.
This gives stability to the adhesives, e.g. against mechanical stress, making the glue more robust to impacts and reducing the retrogradation phenomenon.
Furthermore, you add new flow properties to the glue, getting increased elasticity. This improves adhesiveness and gives increased strength in the adhesive joints.
Reduced glue and steam consumption
“Numerous factory trials of Exilva in the worldwide corrugated market have shown an average glue reduction of around 15%, and we’ve seen results as high as 20%,” says Marvin Hars, Business Development Director, Exilva – Corrugated Board. “In some plants we have measured steam savings due to use of Exilva in the glue.
“It is important to highlight that this product is available immediately, and a test run can be done very easily with little to no risk. We are standby to help you, either remotely or on-site.
“Here are some of our customer learnings:
“Over a 4 weeks trial without any backup from Borregaard, Exilva gave a starch saving of 13,5% when used on Double Backer only.”
– Customer learnings, Plant 1 (native wheat, EU)
“When Exilva was used on both Single Facer and Double Backer, this native wheat based plant gained a starch saving of 16,5%. Added benefits were energy savings from less batches of glue and less steam pressure.”
– Customer learnings, Plant 2 (native wheat, EU)
“By using Exilva on both Single Facer and Double Backer, with native corn, one corrugator experienced a reduced glue consumption of 20%. Steam consumption was also reduced by 8% and downtime in converting was reduced by 20% due to much less post-warp and improved bonding.”
– Customer learnings, Plant 3 (native corn, EU)
“The improved productivity is an added benefit of using Exilva,” Marvin continues.
“We have recorded speed increase of up to 67%, improved board quality, less warp and less complaints, less waste and more robust storage. All of which results in a reduced environmental footprint. These are benefits added on top of the starch savings.
“Our well documented results from about 200 plant trials are proving our claims.”
Examples of increase in production speed on heavy boards combinations:
+33% on double wall BC 250K/110SC/180EK/110SC/250K;
+38% on double wall BC 250K/150SC/200K/150SC/250K;
+42% on medium double wall BC;
+45% on double wall BC 300K/115HP/90R/125HP/300K;
+54% on double wall EC with heavy middle liner and light white liner in the bottom;
+67% on triple wall ACA HK420/WH135/KL275/WH135/KL275/WH135/HK420.
Furthermore, the following positive effects on boards’ quality were demonstrated:
- Less delamination, especially improved bonding at the slitter score section.
For example: Triple wall HK420/WH135/T2210/WH135/T2210/WH135/HK420. - Increased bond strength of cured boards, measured as increased PAT (N/m).
For example: +170% increase for B-flute: 115EK/100WF/115EK. - Flatter board facilitates converting of boards.
Testing Exilva on Glomma Papp has shown that production speed of high quality F-flute corrugated cardboard can reach 200 m/min with no risk of post-wrap.
Exilva can be used in all glue processes and with all kinds of starches: Stein Hall, MiNoCar, No-Carrier; with native and modified wheat, corn, tapioca, pea, potato; and you can go more green with native starch.
Get more information from Marvin Hars, Business Development Director at Exilva – Corrugated Board: [email protected].
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