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Pre-flocculation is a technique that aggregates filler particles by means of polyelectrolytes. The size of the filler flocs is a critical factor affecting the properties of the paper. Process variables including the concentration of the flocculants, the stirring speed, and the dilution of the suspension change the size of the flocculated fillers. Ground calcium carbonate and cationic polyacrylamide were used to investigate the influence of these variables on flocculation. The median particle size and size distribution were examined and the tensile and optical properties influenced by the floc size and ash levels were evaluated. The addition of high concentration C-PAM increased the median particle size. Stirring speeds in the range of 1000 ~ 3000 rpm were used to simulate various turbulent environments, and it was shown that high stirring speeds drastically decreased the floc size. Diluting and low speed stirring the flocculated GCC suspension was effective in keeping the particle size intact without disruption before sheet forming. Larger GCC flocs in the handsheets resulted in better mechanical properties.

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Cationic polyacrylamides (C-PAMs) have been widely used as flocculating agents to aggregate particles carrying negatively charged surfaces. This study examined the effects of hydrolysis of C-PAM on its adsorption behaviour and flocculation of negatively charged particles, specifically ground calcium carbonate (GCC). C-PAM hydrolysis was examined using polyelectrolyte titration and ion chromatography, while the adsorption behaviour of the polymer was monitored using a quartz crystal microbalance with dissipation (QCM-D). Laser diffraction spectroscopy was used to measure the size of the GCC aggregates under neutral and alkaline conditions. The charge density measurements and ion chromatograms indicated that the hydrolysis of C-PAM was accelerated with increased pH and temperature. The QCM-D measurements of hydrolysed C-PAMs, adsorbed on a substrate with a flat and rigid structure, indicated that hydrolysis of C-PAM suppressed its ability to cause inter-particle bridging flocculation, which reduced the aggregate size of GCC.

Papermakers wish to increase the filler content of printing and writing grades because it allows saving in production cost through fiber replacement and improving the formation, and optical and printing properties of the paper. However, high filler loading in the base paper has negative side effects. It reduces the mechanical properties of paper and induces cracking at the fold after coating process. Fold cracking is one of the most frequent quality complaints for magazines, high quality books, etc. Two approaches were examined as methods to reduce fold cracking. One approach was to use preflocculated fillers, which was expected to reduce the fold cracking because it would decrease the interfiber bonding. The other approach was to use a new coating binder that gives greater binding power and thereby provides an opportunity of reducing the fold cracking of coated paper. When filler preflocculation was employed in producing the base paper, fold cracking becomes more severe than conventional filler loading condition. On the other hand, use of nano sized binder in coating improved the tensile properties of the coating layer and thereby decreased the crack area. It was shown that tensile properties of coating layer played an important role in fold cracking of coating.