Barrier coatings applied to nanocellulose-coated paper and paperboard

Abstract

Methods and systems for applying barrier coatings to nanocellulose-coated paper and paperboard.

What is claimed is: 
     
         1 . A method of manufacturing a multi-ply paper or paperboard product, the method comprising:
 (a) providing a consolidating base sheet of pulp following a headbox of a paper or paperboard machine;   (b) applying two or more layers of one or more nanocellulose-containing compositions onto the consolidating base sheet to form a consolidating multi-layer paper or paperboard structured material; and   (c) at a size press section of the paper or paperboard machine, applying a layer to the top of the consolidating multi-layer paper or paperboard structured material, wherein the layer comprises at least one of ethylene vinyl alcohol (EVOH), polyvinyl alcohol (PVOH), starch, surface sizing agent microcrystalline cellulose, and nanocrystalline cellulose,   
       wherein:
 (i) a first layer of nanocellulose-containing composition is applied to the consolidating base sheet in an amount ranging from about 0.1 g/m 2  to about 20 g/m 2 , 
 (ii) a second layer of nanocellulose-containing composition is applied to the consolidating base sheet in an amount ranging from about 1 g/m 2  to about 20 g/m 2 , and 
 (iii) at least one of the first or second layers of nanocellulose-containing composition is applied by spraying. 
 
     
     
         2 . The method according to  claim 1 , wherein the pulp comprises recycled pulp, papermill broke, paper streams rich in mineral fillers, cellulosic materials from a papermill, chemical pulp, thermomechanical pulp, chemi-thermomechanical pulp, mechanical pulp, or a combination thereof. 
     
     
         3 . The method according to  claim 1 or 2 , wherein the pulp comprises recycled paperboard. 
     
     
         4 . The method according to  claim 3 , wherein the recycled paperboard is recycled corrugated containers. 
     
     
         5 . The method according to any one of  claims 1-4 , wherein the nanocellulose comprises nanofibrillated cellulose, microfibrillated cellulose, or a combination thereof. 
     
     
         6 . The method according to any one of  claims 1-5 , wherein the nanocellulose comprises microcrystalline cellulose, nanocrystalline cellulose, cellulose nanocrystals (CNCs), or a combination thereof. 
     
     
         7 . The method according to any one of  claims 1-6 , wherein the nanocellulose is produced from hardwood pulp, softwood pulp, wheat straw pulp, bamboo, bagasse, virgin fiber, chemical pulp, chemithermomechanical pulp, mechanical pulp, thermomechanical pulp, kraft pulp, bleached long fibre kraft pulp, eucalyptus pulp, spruce pulp, pine pulp, beech pulp, hemp pulp, acacia cotton pulp, recycled pulp, papermill broke, paper steam rich in mineral fillers, or a combination thereof. 
     
     
         8 . The method according to  claim 7 , wherein the hardwood pulp is selected from the group consisting of eucalyptus, aspen, birch, and mixed hardwood pulps. 
     
     
         9 . The method according to  claim 7 , wherein the softwood pulp is selected from the group consisting of spruce, pine, fir, larch, hemlock, and mixed softwood pulp. 
     
     
         10 . The method according to any one of  claims 1-9 , further comprising applying one or more additional layers atop the two or more layers of one or more nanocellulose-containing compositions, wherein the one or more additional layers comprise one or more of a barrier layer, a wax layer, and a silicon layer. 
     
     
         11 . The method according to any one of  claims 1-9 , further comprising applying an additional layer atop the two or more layers of one or more nanocellulose-containing compositions, wherein the additional layer consists essentially of inorganic particulate material and microfibrillated cellulose. 
     
     
         12 . The method according to  claim 11 , wherein the inorganic particulate material comprises calcium carbonate, ground calcium carbonate, precipitated calcium carbonate, magnesium carbonate, dolomite, gypsum, an anhydrous kandite clay, kaolin, perlite, bentonite, diatomaceous earth, wollastonite, talc, magnesium hydroxide, titanium dioxide, or aluminium trihydrate, or a combination thereof. 
     
     
         13 . The method according to  claim 12 , wherein the inorganic particulate material comprises ground calcium carbonate and precipitated calcium carbonate. 
     
     
         14 . The method according to any one of  claims 1-10 , wherein the two or more layers, of the one or more nanocellulose-containing compositions, are applied via spraying. 
     
     
         15 . The method according to any one of  claims 1-10 , wherein:
 the first layer is applied using a slotted applicator; and   the second layer is applied using spraying.   
     
     
         16 . The method according to  claim 15 , wherein the slotted applicator is a slot coater. 
     
     
         17 . The method according to  claim 15 , wherein the slotted applicator is a curtain coater. 
     
     
         18 . The method according to any one of  claims 1-10 , wherein applying the two or more layers, of the one or more nanocellulose-containing compositions, causes the consolidating multi-layer paper or paperboard structured material to have a heptane vapor transmission rate of about 0 g m −2  day −1  to about 2,500 g m −2  day −1 . 
     
     
         19 . The method according to  claim 18 , wherein applying the two or more layers, of the one or more nanocellulose-containing compositions, causes the consolidating multi-layer paper or paperboard structured material to have a heptane vapor transmission rate of about 0 g m −2  day −1  to about 100 g m −2  day −1 . 
     
     
         20 . The method according to any one of  claims 1-10 , wherein at least one of the two or more layers, of the one or more nanocellulose-containing compositions, is applied across substantially the entire width of the consolidating base sheet. 
     
     
         21 . The method according to any one of  claims 1-10 , wherein at least one of the two or more layers, of the one or more nanocellulose-containing compositions, is applied across the entire width of the consolidating base sheet. 
     
     
         22 . The method according to any one of  claims 1-10 , wherein:
 the one or more nanocellulose-containing compositions comprises a first nanocellulose-containing composition; and   the first nanocellulose-containing composition comprises nanofibrillated cellulose, microfibrillated cellulose, or a combination thereof.   
     
     
         23 . The method according to any one of  claims 1-10  wherein:
 the one or more nanocellulose-containing compositions comprises a first nanocellulose-containing composition; and 
 the first nanocellulose-containing composition comprises microcrystalline cellulose, nanocrystalline cellulose, cellulose nanocrystals (CNCs), or a combination thereof. 
 
     
     
         24 . The method according to  claim 22 , wherein the first nanocellulose containing composition comprises first nanocellulose in a range of about 0.5 wt % to about 6 wt % based on the total weight of the first nanocellulose-containing composition. 
     
     
         25 . The method according to  claim 24 , wherein the first nanocellulose-containing composition comprises first nanocellulose in a range of about 1 wt % to about 2 wt % based on the total weight of the first nanocellulose-containing composition. 
     
     
         26 . The method according to  claim 22 , wherein the first nanocellulose-containing composition comprises at least about 0.5 wt % first nanocellulose based on the total weight of the first nanocellulose-containing composition. 
     
     
         27 . The method according to  claim 26 , wherein the first nanocellulose-containing composition comprises at least about 1 wt % first nanocellulose based on the total weight of the first nanocellulose-containing composition. 
     
     
         28 . The method according to  claim 22 , wherein the first nanocellulose-containing composition comprises at most about 6 wt % first nanocellulose based on the total weight of the first nanocellulose-containing composition. 
     
     
         29 . The method according to  claim 28 , wherein the first nanocellulose-containing composition comprises at most about 3 wt % first nanocellulose based on the total weight of the first nanocellulose-containing composition. 
     
     
         30 . The method according to  claim 29 , wherein the first nanocellulose-containing composition comprises at most about 2 wt % first nanocellulose based on the total weight of the first nanocellulose-containing composition. 
     
     
         31 . The method according to  claim 22 , wherein the first nanocellulose-containing composition comprises one or more inorganic particulate material. 
     
     
         32 . The method according to  claim 31 , wherein the one or more inorganic particulate material comprises bentonite, alkaline earth metal carbonate, alkaline earth metal sulphate, dolomite, gypsum, hydrous kandite clay, anhydrous calcined kandite clay, talc, mica, perlite, diatomaceous earth, magnesium hydroxide, aluminum trihydrate, or a combination thereof. 
     
     
         33 . The method according to  claim 32 , wherein the one or more inorganic particulate material is bentonite. 
     
     
         34 . The method according to  claim 22 , wherein the first nanocellulose-containing composition comprises one or more starches. 
     
     
         35 . The method according to  claim 34 , wherein the one or more starches are one or more cationic starches. 
     
     
         36 . The method according to  claim 22 , wherein the first nanocellulose-containing composition comprises one or more sizing agents. 
     
     
         37 . The method according to  claim 36 , wherein the one or more sizing agents comprise rosin, rosin/aluminum emulsion, cationic rosin emulsion, alkylketene dimer, wax emulsion, succinic acid derivative, or a combination thereof. 
     
     
         38 . The method according to  claim 37 , wherein the succinic acid derivative is alkenylsuccinic anhydride. 
     
     
         39 . The method according to  claim 22 , wherein the first nanocellulose-containing composition comprises one or more polyacrylamides. 
     
     
         40 . The method according to  claim 39 , wherein the one or more polyacrylamides comprise polydiallyldimethylammonium chloride (polyDADMAC). 
     
     
         41 . The method according to  claim 22 , wherein the first nanocellulose-containing composition comprises one or more copolymers. 
     
     
         42 . The method according to  claim 41 , wherein the one or more copolymers comprise ethylene vinyl alcohol (EVOH), polyvinyl alcohol (PVOH), or a combination thereof. 
     
     
         43 . The method according to any one of  claims 1-10 , wherein:
 the one or more nanocellulose-containing compositions comprise a first nanocellulose-containing composition and a second nanocellulose-containing composition; and   both the first nanocellulose-containing composition and the second nanocellulose-containing composition are applied via spraying.   
     
     
         44 . The method according to any one of  claims 1-10 , wherein:
 the one or more nanocellulose-containing compositions comprise a first nanocellulose containing composition and a second nanocellulose containing composition;   the first nanocellulose-containing composition is applied using a slotted applicator; and   the second nanocellulose-containing composition is applied using spraying.   
     
     
         45 . The method according to  claim 44 , wherein the slotted applicator is a slot coater. 
     
     
         46 . The method according to  claim 44 , wherein the slotted applicator is a curtain coater. 
     
     
         47 . The method according to  claim 43 , wherein:
 the first nanocellulose-containing composition has a first particle size distribution;   the second nanocellulose-containing composition has a second particle size distribution from 5 μm to 500 μm; and   the mean size, of the first particle size distribution, is greater than the mean size of the second particle size distribution.   
     
     
         48 . The method according to  claim 43 , wherein the first nanocellulose-containing composition comprises first nanocellulose having a first Fines B % by fibre analyzer, the second nanocellulose-containing composition comprises second nanocellulose having a second Fines B % by fibre analyzer, and the first Fines B % by fibre analyzer is lower than the second Fines B % by fibre analyzer. 
     
     
         49 . The method according to  claim 44 , wherein the first nanocellulose-containing composition comprises first nanocellulose having a first Fines B % by fibre analyzer, the second nanocellulose-containing composition comprises second nanocellulose having a second Fines B % by fibre analyzer, and the first Fines B % by fibre analyzer is lower than the second Fines B % by fibre analyzer. 
     
     
         50 . The method according to  claim 48 , wherein applying the second nanocellulose-containing composition causes the consolidating base sheet to have a heptane vapor transmission rate of about 0 g m −2  day −1  to about 2,500 g m −2  day −1 . 
     
     
         51 . The method according to  claim 50 , wherein applying the second nanocellulose-containing composition causes the consolidating base sheet to have a heptane vapor transmission rate of about 0 g m −2  day −1  to about 100 g m −2  day −1 . 
     
     
         52 . The method according to  claim 49 , wherein applying the second nanocellulose-containing composition causes the consolidating base sheet to have a heptane vapor transmission rate of about 0 g m −2  day −1  to about 2,500 g m −2  day −1 . 
     
     
         53 . The method according to  claim 52 , wherein applying the second nanocellulose-containing composition causes the consolidating base sheet to have a heptane vapor transmission rate of about 0 g m −2  day −1  to about 100 g m −2  day −1 . 
     
     
         54 . The method according to  claim 48 , wherein the second nanocellulose-containing composition comprises nanofibrillated cellulose, microfibrillated cellulose, or a combination thereof. 
     
     
         55 . The method according to  claim 49 , wherein the second nanocellulose-containing composition comprises nanofibrillated cellulose, microfibrillated cellulose, or a combination thereof. 
     
     
         56 . The method according to  claim 48 , wherein the second nanocellulose-containing composition comprises nanocellulose in a range of about 0.5 wt % to about 6 wt % based on the total weight of the second nanocellulose-containing composition. 
     
     
         57 . The method according to  claim 49 , wherein the second nanocellulose-containing composition comprises nanocellulose in a range of about 0.5 wt % to about 6 wt % based on the total weight of the second nanocellulose-containing composition. 
     
     
         58 . The method according to  claim 48 , wherein the second nanocellulose-containing composition comprises at least about 0.5 wt % nanocellulose based on the total weight of the second nanocellulose-containing composition. 
     
     
         59 . The method according to  claim 49 , wherein the second nanocellulose-containing composition comprises at least about 0.5 wt % nanocellulose based on the total weight of the second nanocellulose-containing composition. 
     
     
         60 . The method according to  claim 48 , wherein the second nanocellulose-containing composition comprises at most about 6 wt % nanocellulose based on the total weight of the second nanocellulose-containing composition. 
     
     
         61 . The method according to  claim 49 , wherein the second nanocellulose-containing composition comprises at most about 6 wt % nanocellulose based on the total weight of the second nanocellulose-containing composition. 
     
     
         62 . The method according to  claim 48 , wherein the first nanocellulose containing composition comprises one or more inorganic particulate material. 
     
     
         63 . The method according to  claim 49 , wherein the first nanocellulose containing composition comprises one or more inorganic particulate material. 
     
     
         64 . The method according to  claim 62 , wherein the one or more inorganic particulate material comprise bentonite, alkaline earth metal carbonate, alkaline earth metal sulphate, dolomite, gypsum, hydrous kandite clay, anhydrous calcined kandite clay, talc, mica, perlite, diatomaceous earth, magnesium hydroxide, aluminum trihydrate, or a combination thereof 
     
     
         65 . The method according to  claim 63 , wherein the one or more inorganic particulate material comprise bentonite, alkaline earth metal carbonate, alkaline earth metal sulphate, dolomite, gypsum, hydrous kandite clay, anhydrous calcined kandite clay, talc, mica, perlite, diatomaceous earth, magnesium hydroxide, aluminum trihydrate, or a combination thereof. 
     
     
         66 . The method according to  claim 48 , wherein the second nanocellulose containing composition comprises one or more cationic starches. 
     
     
         67 . The method according to  claim 49 , wherein the second nanocellulose containing composition comprises one or more cationic starches. 
     
     
         68 . The method according to  claim 48 , wherein the second nanocellulose containing composition comprises one or more sizing agents. 
     
     
         69 . The method according to  claim 49 , wherein the second nanocellulose containing composition comprises one or more sizing agents. 
     
     
         70 . The method according to  claim 48 , wherein the second nanocellulose containing composition comprises one or more polyacrylamides. 
     
     
         71 . The method according to  claim 49 , wherein the second nanocellulose containing composition comprises one or more polyacrylamides. 
     
     
         72 . The method according to  claim 48 , wherein the second nanocellulose containing composition comprises one or more copolymers. 
     
     
         73 . The method according to  claim 49 , wherein the second nanocellulose containing composition comprises one or more copolymers. 
     
     
         74 . The method according to  claim 72 , wherein the one or more copolymers comprise ethylene vinyl alcohol (EVOH), polyvinyl alcohol (PVOH), or a combination thereof. 
     
     
         75 . The method according to  claim 73 , wherein the one or more copolymers comprise ethylene vinyl alcohol (EVOH), polyvinyl alcohol (PVOH), or a combination thereof. 
     
     
         76 . The method according to any one of  claims 1-10 , wherein cationic starch is applied to the consolidating multi-layer paper or paperboard structured material at the size press section. 
     
     
         77 . The method according to any one of  claims 1-10 , wherein a surface sizing agent is applied to the consolidating multi-layer paper or paperboard structured material at the size press section. 
     
     
         78 . The method according to  claim 77 , wherein the surface sizing agent, applied to the consolidating multi-layer paper or paperboard structured material at the size press section, is selected from the group consisting of rosin, rosin/aluminum emulsion, cationic rosin emulsion, alkylketene dimer, wax emulsion, and succinic acid derivative. 
     
     
         79 . The method according to  claim 78 , wherein the succinic acid derivative is alkenylsuccinic anhydride. 
     
     
         80 . A paper or paperboard manufactured according to any one of  claims 1-10 . 
     
     
         81 . The paper or paperboard according to  claim 80 , wherein the paper or paperboard comprises a base layer having a grammage ranging from about 25 g/m 2  to about 500 g/m 2 . 
     
     
         82 . The paper or paperboard according to  claim 80 , wherein the paper or paperboard is a white top containerboard. 
     
     
         83 . A system for producing a paper or paperboard, the system comprising:
 a headbox configured to output a consolidating base sheet;   means for sequentially applying two or more layers of a nanocellulose-containing composition onto the surface of the consolidating base sheet, wherein at least one of the two or more layers is sprayed onto the consolidating base sheet; and   a size press section comprising means for applying a layer to the top of the consolidating base sheet, wherein the layer comprises at least one of ethylene vinyl alcohol (EVOH), polyvinyl alcohol (PVOH), starch, surface sizing agent, microcrystalline cellulose, and nanocrystalline cellulose.   
     
     
         84 . The system according to  claim 83 , wherein the means for sequentially applying comprises:
 a first spray boom configured to spray a first layer of the nanocellulose-containing composition, onto the surface of the consolidating base sheet; and   a second spray boom configured to spray a second layer of the nanocellulose-containing composition, onto the surface of the consolidating base sheet.   
     
     
         85 . The system according to  claim 83 , wherein the means for sequentially applying comprises:
 a slotted applicator configured to apply a first layer of the nanocellulose-containing composition, onto the surface of the consolidating base sheet; and   a spray boom configured to spray a second layer of the nanocellulose-containing composition, onto the surface of the consolidating base sheet.   
     
     
         86 . The method according to  claim 85 , wherein the slotted applicator is a slot coater. 
     
     
         87 . The method according to  claim 85 , wherein the slotted applicator is a curtain coater. 
     
     
         88 . The system according to any one of  claims 84-87 , wherein the second layer causes the consolidating base sheet to have a heptane vapor transmission rate of about 0 g m −2  day −1  to about 2,500 g m −2  day −1 . 
     
     
         89 . The system according to  claim 88 , wherein the second layer causes the consolidating base sheet to have a heptane vapor transmission rate of about 0 g m −2  day −1  to about 100 g m −2  day −1 . 
     
     
         90 . The system according to any one of  claims 83-89 , wherein at least one of the two or more layers is applied across substantially the entire width of the consolidating base sheet. 
     
     
         91 . The system according to any one of  claims 83-89 , wherein at least one of the two or more layers is applied across the entire width of the consolidating base sheet. 
     
     
         92 . The system according to any one of  claims 83-89 , wherein the nanocellulose-containing composition comprises nanofibrillated cellulose, microfibrillated cellulose, or a combination thereof. 
     
     
         93 . The system according to any one of  claims 83-89 , wherein the nanocellulose-containing composition comprises microcrystalline cellulose, nanocrystalline cellulose, cellulose nanocrystals (CNCs), or a combination thereof. 
     
     
         94 . The system according to any one of  claims 83-89 , wherein the nanocellulose-containing composition comprises nanocellulose in a range of about 0.5 wt % to about 6 wt % based on the total weight of the nanocellulose-containing composition. 
     
     
         95 . The system according to  claim 94 , wherein the nanocellulose-containing composition comprises nanocellulose in a range of about 1 wt % to about 2 wt % based on the total weight of the nanocellulose-containing composition. 
     
     
         96 . The system according to any one of  claims 83-89 , wherein the nanocellulose-containing composition comprises at least about 0.5 wt % nanocellulose based on the total weight of the nanocellulose-containing composition. 
     
     
         97 . The system according to  claim 96 , wherein the nanocellulose-containing composition comprises at least about 1 wt % nanocellulose based on the total weight of the nanocellulose-containing composition. 
     
     
         98 . The system according to any one of  claims 83-89 , wherein the nanocellulose-containing composition comprises at most about 6 wt % nanocellulose based on the total weight of the nanocellulose-containing composition. 
     
     
         99 . The system according to  claim 98 , wherein the nanocellulose-containing composition comprises at most about 3 wt % nanocellulose based on the total weight of the nanocellulose-containing composition. 
     
     
         100 . The system according to  claim 99 , wherein the nanocellulose-containing composition comprises at most about 2 wt % nanocellulose based on the total weight of the nanocellulose-containing composition. 
     
     
         101 . The system according to any one of  claims 83-89 , wherein the nanocellulose-containing composition comprises one or more inorganic particulate material. 
     
     
         102 . The system according to  claim 101 , wherein the one or more inorganic particulate material comprises bentonite, alkaline earth metal carbonate, alkaline earth metal sulphate, dolomite, gypsum, hydrous kandite clay, anhydrous calcined kandite clay, talc, mica, perlite, diatomaceous earth, magnesium hydroxide, aluminum trihydrate, or a combination thereof. 
     
     
         103 . The system according to  claim 102 , wherein the one or more inorganic particulate material is bentonite. 
     
     
         104 . The system according to any one of  claims 83-89 , wherein the nanocellulose-containing composition comprises one or more starches. 
     
     
         105 . The system according to  claim 104 , wherein the one or more starches are one or more cationic starches. 
     
     
         106 . The system according to any one of  claims 83-89 , wherein the nanocellulose-containing composition comprises one or more sizing agents. 
     
     
         107 . The system according to  claim 106 , wherein the one or more sizing agents comprise rosin, rosin/aluminum emulsion, cationic rosin emulsion, alkylketene dimer, wax emulsion, succinic acid derivative, or a combination thereof. 
     
     
         108 . The system according to  claim 107 , wherein the succinic acid derivative is alkenylsuccinic anhydride. 
     
     
         109 . The system according to any one of  claims 83-89 , wherein the nanocellulose-containing composition comprises one or more polyacrylamides. 
     
     
         110 . The system according to  claim 109 , wherein the one or more polyacrylamides comprise polydiallyldimethylammonium chloride (polyDADMAC). 
     
     
         111 . The system according to any one of  claims 83-89 , wherein the nanocellulose-containing composition comprises one or more copolymers. 
     
     
         112 . The system according to  claim 111 , wherein the one or more copolymers comprise ethylene vinyl alcohol (EVOH), polyvinyl alcohol (PVOH), or a combination thereof. 
     
     
         113 . The system according to any one of  claims 83-89 , wherein the starch, applied to the consolidating base sheet at the size press section, comprises one or more cationic starches. 
     
     
         114 . The system according to any one of  claims 83-89 , wherein the surface sizing agent, applied to the consolidating base sheet at the size press section, comprises rosin, rosin/aluminum emulsion, cationic rosin emulsion, alkylketene dimer, wax emulsion, succinic acid derivative, or a combination thereof. 
     
     
         115 . The system according to any one of  claims 83-89 , wherein the surface sizing agent, applied to the consolidating base sheet at the size press section, is selected from the group consisting of rosin, rosin/aluminum emulsion, cationic rosin emulsion, alkylketene dimer, wax emulsion, and succinic acid derivative. 
     
     
         116 . The system according to  claim 114 , wherein the succinic acid derivative is alkenylsuccinic anhydride. 
     
     
         117 . A system of producing a paper or paperboard, the system comprising:
 a headbox configured to output a consolidating base sheet;   a first means for applying a first layer of a first nanocellulose-containing composition onto the surface of the consolidating base sheet;   a second means for applying a second layer of a second nanocellulose-containing composition onto the surface of the consolidating base sheet; and   a size press section comprising means for applying a layer to the top of the consolidating base sheet, wherein the layer comprises at least one of ethylene vinyl alcohol (EVOH), polyvinyl alcohol (PVOH), starch, surface sizing agent, microcrystalline cellulose, and nanocrystalline cellulose,   wherein at least one of the first layer or the second layer is sprayed onto the consolidating base sheet.   
     
     
         118 . The system according to  claim 117 , wherein:
 the first means is a first spray boom configured to spray the first layer onto the surface of the consolidating base sheet; and   the second means is a second spray boom configured to spray the second layer onto the surface of the consolidating base sheet.   
     
     
         119 . The system according to  claim 117 , wherein:
 the first means is a slotted applicator configured to apply the first layer onto the surface of the consolidating base sheet; and   the second means is a spray boom configured to spray the second layer onto the surface of the consolidating base sheet.   
     
     
         120 . The system according to  claim 119 , wherein the slotted applicator is a slot coater. 
     
     
         121 . The system according to  claim 119 , wherein the slotted applicator is a curtain coater. 
     
     
         122 . The system according to any one of  claims 117-121 , wherein:
 the first nanocellulose-containing composition has a first particle size distribution;   the second nanocellulose-containing composition has a second particle size distribution; and   the mean size, of the first particle size distribution is greater than the mean size of the second particle size distribution.   
     
     
         123 . The system according to  claim 122 , wherein the mean size, of the first particle size distribution of the first nanocellulose-containing composition, is from 5 μm to 500 μm. 
     
     
         124 . The system according to  claim 122 , wherein the mean size, of the second particle size distribution of the second nanocellulose-containing composition, is from 5 μm to 500 μm. 
     
     
         125 . The system according to any one of  claims 117-121 , wherein the second nanocellulose-containing composition causes the consolidating base sheet to have a heptane vapor transmission rate of about 0 g m −2  day −1  to about 2,500 g m −2  day −1 . 
     
     
         126 . The system according to  claim 125 , wherein the second nanocellulose-containing composition causes the consolidating base sheet to have a heptane vapor transmission rate of about 0 g m −2  day −1  to about 100 g m −2  day −1 . 
     
     
         127 . The system according to any one of  claims 117-121 , wherein at least one of the first nanocellulose-containing composition and the second nanocellulose-containing composition is applied across substantially the entire width of the consolidating base sheet. 
     
     
         128 . The system according to any one of  claims 117-121 , wherein at least one of the first nanocellulose-containing composition and the second nanocellulose-containing composition is applied across the entire width of the consolidating base sheet. 
     
     
         129 . The system according to any one of  claims 117-121 , wherein the first nanocellulose-containing composition comprises nanofibrillated cellulose, microfibrillated cellulose, or a combination thereof. 
     
     
         130 . The system according to any one of  claims 117-121 , wherein the first nanocellulose-containing composition comprises microcrystalline cellulose, nanocrystalline cellulose, cellulose nanocrystals (CNCs), or a combination thereof. 
     
     
         131 . The system according to any one of  claims 117-121 , wherein the first nanocellulose-containing composition comprises nanocellulose in a range of about 0.5 wt % to about 6 wt % based on the total weight of the first nanocellulose-containing composition. 
     
     
         132 . The system according to  claim 131 , wherein the first nanocellulose-containing composition comprises nanocellulose in a range of about 1 wt % to about 2 wt % based on the total weight of the first nanocellulose-containing composition. 
     
     
         133 . The system according to any one of  claims 117-121 , wherein the first nanocellulose-containing composition comprises at least about 0.5 wt % nanocellulose based on the total weight of the first nanocellulose-containing composition. 
     
     
         134 . The system according to  claim 133 , wherein the first nanocellulose-containing composition comprises at least about 1 wt % nanocellulose based on the total weight of the first nanocellulose-containing composition. 
     
     
         135 . The system according to any one of  claims 117-121 , wherein the first nanocellulose-containing composition comprises at most about 6 wt % nanocellulose based on the total weight of the first nanocellulose-containing composition. 
     
     
         136 . The system according to  claim 135 , wherein the first nanocellulose-containing composition comprises at most about 3 wt % nanocellulose based on the total weight of the first nanocellulose-containing composition. 
     
     
         137 . The system according to  claim 136 , wherein the first nanocellulose-containing composition comprises at most about 2 wt % nanocellulose based on the total weight of the first nanocellulose-containing composition. 
     
     
         138 . The system according to any one of  claims 117-121 , wherein the second nanocellulose-containing composition comprises nanofibrillated cellulose, microfibrillated cellulose, or a combination thereof. 
     
     
         139 . The system according to any one of  claims 117-121 , wherein the second nanocellulose-containing composition comprises microcrystalline cellulose, nanocrystalline cellulose, cellulose nanocrystals (CNCs), or a combination thereof. 
     
     
         140 . The system according to any one of  claims 117-121 , wherein the second nanocellulose-containing composition comprises nanocellulose in a range of about 0.5 wt % to about 6 wt % based on the total weight of the second nanocellulose-containing composition. 
     
     
         141 . The system according to  claim 140 , wherein the second nanocellulose-containing composition comprises nanocellulose in a range of about 1 wt % to about 2 wt % based on the total weight of the second nanocellulose-containing composition. 
     
     
         142 . The system according to any one of  claims 117-121 , wherein the second nanocellulose-containing composition comprises at least about 0.5 wt % nanocellulose based on the total weight of the second nanocellulose-containing composition. 
     
     
         143 . The system according to  claim 142 , wherein the second nanocellulose-containing composition comprises at least about 1 wt % nanocellulose based on the total weight of the second nanocellulose-containing composition. 
     
     
         144 . The system according to any one of  claims 117-121 , wherein the second nanocellulose-containing composition comprises at most about 6 wt % nanocellulose based on the total weight of the second nanocellulose-containing composition. 
     
     
         145 . The system according to  claim 144 , wherein the second nanocellulose-containing composition comprises at most about 3 wt % nanocellulose based on the total weight of the second nanocellulose-containing composition. 
     
     
         146 . The system according to  claim 145 , wherein the second nanocellulose-containing composition comprises at most about 2 wt % nanocellulose based on the total weight of the second nanocellulose-containing composition. 
     
     
         147 . The system according to any one of  claims 117-121 , wherein at least one of the first nanocellulose-containing composition and the second nanocellulose containing composition comprises one or more inorganic particulate material. 
     
     
         148 . The system according to  claim 147 , wherein:
 the first nanocellulose-containing composition comprises the one or more inorganic particulate material; and   the second nanocellulose-containing composition is free of inorganic particulate material.   
     
     
         149 . The system according to  claim 147 , wherein the one or more inorganic particulate material comprises bentonite, alkaline earth metal carbonate, alkaline earth metal sulphate, dolomite, gypsum, hydrous kandite clay, anhydrous calcined kandite clay, talc, mica, perlite, diatomaceous earth, magnesium hydroxide, aluminum trihydrate, or a combination thereof. 
     
     
         150 . The system according to  claim 149 , wherein the one or more inorganic particulate material is bentonite. 
     
     
         151 . The system according to any one of  claims 117-121 , wherein at least one of the first nanocellulose-containing composition and the second nanocellulose containing composition comprises one or more starches. 
     
     
         152 . The system according to  claim 151 , wherein the one or more starches comprise one or more cationic starches. 
     
     
         153 . The system according to any one of  claims 117-121 , wherein at least one of the first nanocellulose-containing composition and the second nanocellulose containing composition comprises one or more sizing agents. 
     
     
         154 . The system according to  claim 153 , wherein the one or more sizing agents comprise rosin, rosin/aluminum emulsion, cationic rosin emulsion, alkylketene dimer, wax emulsion, succinic acid derivative, or a combination thereof. 
     
     
         155 . The system according to  claim 154 , wherein the succinic acid derivative is alkenylsuccinic anhydride. 
     
     
         156 . The system according to any one of  claims 117-121 , wherein at least one of the first nanocellulose-containing composition and the second nanocellulose containing composition comprises one or more polyacrylamides. 
     
     
         157 . The system according to  claim 156 , wherein the one or more polyacrylamides comprise polydiallyldimethylammonium chloride (polyDADMAC). 
     
     
         158 . The system according to any one of  claims 117-121 , wherein at least one of the first nanocellulose-containing composition and the second nanocellulose containing composition comprises one or more copolymers. 
     
     
         159 . The system according to  claim 158 , wherein the one or more copolymers comprise ethylene vinyl alcohol (EVOH), polyvinyl alcohol (PVOH), or a combination thereof. 
     
     
         160 . The system according to any one of  claims 117-121 , wherein the starch applied to the consolidating base sheet at the size press section, comprises one or more cationic starches. 
     
     
         161 . The method according to any one of  claims 117-121 , wherein the surface sizing agent applied to the consolidating base sheet at the size press section, comprises rosin, rosin/aluminum emulsion, cationic rosin emulsion, alkylketene dimer, wax emulsion, succinic acid derivative, or a combination thereof. 
     
     
         162 . The method according to any one of  claims 117-121 , wherein the surface sizing agent applied to the consolidating base sheet at the size press section, is selected from the group consisting of rosin, rosin/aluminum emulsion, cationic rosin emulsion, alkylketene dimer, wax emulsion, and succinic acid derivative. 
     
     
         163 . The method according to  claim 161 or 162 , wherein the succinic acid derivative is alkenylsuccinic anhydride. 
     
     
         164 . The system according to any one of  claims 117-121 , wherein the first nanocellulose-containing composition comprises first nanocellulose having a first Fines B % by fibre analyzer, the second nanocellulose-containing composition comprises second nanocellulose having a second Fines B % by fibre analyzer, and the first Fines B % by fibre analyzer is lower than the second Fines B % by fibre analyzer. 
     
     
         165 . The method according to any one of  claims 83-89 , wherein the first nanocellulose-containing composition comprises first nanocellulose having a first Fines B % by fibre analyzer, the second nanocellulose-containing composition comprises second nanocellulose having a second Fines B % by fibre analyzer, and the first Fines B % by fibre analyzer is lower than the second Fines B % by fibre analyzer.