Case Study: How Bluwat Polyacrylamide Improved Retention and Water Reuse in Papermaking

Region: Southeast Asia | Paper Grade: Packaging Paper (Testliner & Fluting)

Background

A medium-to-large paper mill located in Southeast Asia specializes in the production of packaging paper, mainly testliner and fluting, using recycled OCC pulp.

With increasing raw material costs and stricter environmental requirements, the mill faced several challenges:

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

• Unstable drainage and inconsistent sheet formation

• High turbidity in white water, limiting reuse

• Rising freshwater consumption and wastewater treatment costs

The mill was looking for a practical chemical solution that could improve efficiency without major equipment modification.

Initial Process Conditions

• Raw material: Recycled OCC pulp

• Paper grades: Testliner & Fluting (120–180 g/m²)

• Filler content: Moderate

• Wet-end pH: Neutral to slightly alkaline

• White water condition: High suspended solids, visible turbidity

Bluwat Solution Approach

After laboratory evaluation and on-site trials, Bluwat proposed a step-by-step polyacrylamide solution, targeting different stages of the papermaking process:

Products Applied:

• 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. Improving Retention in the Wet-End System

Product: Blufloc C8020 / C8030

Blufloc C8020 and C8030 were dosed at the fan pump / headbox area to improve the retention of fine fibers and fillers.

Observed improvements:

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

• White water suspended solids decreased significantly

• Drainage became more stable, reducing vacuum load

• Sheet formation improved with fewer defects

The improved retention directly reduced raw material loss and stabilized paper machine operation.

2. Enhancing Paper Strength Performance

Product: Blufloc AA5412

To improve paper strength, Blufloc AA5412 was introduced as a dry strength additive.

Results after optimization:

• Noticeable improvement in tensile and burst strength

• Better folding endurance, especially for fluting grades

• More uniform paper structure and improved printability

This allowed the mill to maintain strength specifications while optimizing fiber usage, supporting cost reduction.

3. White Water Clarification and Reuse

Product: Blufloc AA5516

High turbidity in white water previously limited reuse.
Blufloc AA5516 was applied in the white water clarification system, in combination 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 white water reused in the papermaking process

As a result, the mill significantly reduced freshwater intake and wastewater discharge.

Overall Results Achieved

After implementing the Bluwat polyacrylamide solution, the mill achieved:

✔ Higher retention of fibers and fillers
✔ Improved paper strength and quality consistency
✔ Effective white water reuse and reduced water consumption
✔ Lower chemical and raw material costs
✔ Improved environmental compliance

Conclusion

This case demonstrates how a properly selected polyacrylamide system can deliver measurable improvements in retention, strength, and water management in packaging paper production.

Bluwat’s Blufloc series provides tailored PAM solutions for papermaking, helping mills achieve higher efficiency, lower costs, and more sustainable operation.