Systems and methods for production of starch-loaded fibrillated fibers

Abstract

A method of making a pulp composition having improved strength characteristics is disclosed. The method includes mixing together a starch and fibrillated fibers to produce a starch/fibrillated fibers mixture, and mixing the starch/fibrillated fibers mixture into wood pulp fibers to produce the pulp composition.

What is claimed is: 
     
         1 . A method of making a pulp composition, the method comprising:
 mixing together a starch and fibrillated fibers to produce a starch/fibrillated fibers mixture; and   mixing the starch/fibrillated fibers mixture into wood pulp fibers to produce the pulp composition.   
     
     
         2 . The method of  claim 1 , wherein the wood pulp fibers comprise one or more of hardwood pulp fibers, softwood pulp fibers, non-wood pulp, recycled pulp fibers, or combinations thereof. 
     
     
         3 . The method of  claim 2 , further comprising:
 depositing the pulp composition onto a web to form a substrate;   at least partially dewatering the substrate; and   drying the substrate to form a paper product.   
     
     
         4 . The method of  claim 3 , wherein the fibrillated fibers comprise surface enhanced pulp fibers (SEPF). 
     
     
         5 . The method of  claim 4 , wherein the paper product comprises approximately 0.1 to 2.5 weight percent starch, approximately 2 to 20 weight percent SEPF, and approximately 83 to 97 weight percent wood pulp fibers. 
     
     
         6 . The method of  claim 5 , wherein the paper product comprises approximately 0.4 to 2.0 weight percent starch, approximately 3 to 17 weight percent SEPF, and approximately 83 to 97 weight percent wood pulp fibers. 
     
     
         7 . The method of  claim 6 , wherein the paper product has a Breaking Length of at least approximately 7.0 km. 
     
     
         8 . The method of  claim 7 , wherein the paper product has a Tensile Energy Absorption (TEA) of at least approximately 110 J/m 2 . 
     
     
         9 . The method of  claim 8 , wherein the paper product has a Tear Index of less than at least approximately 9.6 mN·m 2 /g. 
     
     
         10 . The method of  claim 4 , wherein the paper product comprises approximately 0.8 percent starch, approximately 10 percent SEPF, and approximately 90 percent wood pulp fibers. 
     
     
         11 . The method of  claim 10 , wherein the paper product has a Breaking Length of at least approximately 7.0 km. 
     
     
         12 . The method of  claim 11 , wherein the paper product has a Tensile Energy Absorption (TEA) of at least approximately 106 J/m 2 . 
     
     
         13 . A method of making a paper product, the method comprising:
 mixing together a starch and fibrillated fibers to produce a starch/fibrillated fibers mixture;   mixing the starch/fibrillated fibers mixture into wood pulp fibers to produce a pulp composition;   depositing the pulp composition onto a web to form a substrate;   at least partially dewatering the substrate; and   drying the substrate to form the paper product, wherein the paper product has an increased Breaking Length compared to a First Comparative Paper Product.   
     
     
         14 . A paper product comprising:
 a starch in a first amount in the range of approximately 0.1 to 2.5 weight percent;   fibrillated fibers in a second amount in the range of approximately 2 to 20 weight percent; and   wood pulp fibers in a third amount in the range of approximately 83 to 97 weight percent,   wherein the paper product has a lower amount of the starch compared to a Second Comparative Paper Product; and   wherein the paper product maintains a Breaking Length within the range of approximately 10 percent compared to a Second Comparative Paper Product.   
     
     
         15 . The paper product of  claim 14 , wherein the paper produce maintains a Breaking Length within the range of approximately 2 percent compared to a Second Comparative Paper Product. 
     
     
         16 . The paper product of  claim 14 , wherein the paper product comprises approximately 0.1 to 2.5 weight percent starch, approximately 2 to 20 weight percent SEPF, and approximately 83 to 97 weight percent wood pulp fibers. 
     
     
         17 . The paper product of  claim 16 , wherein the paper product comprises approximately 0.4 to 2.0 weight percent starch, approximately 3 to 17 weight percent SEPF, and approximately 83 to 97 weight percent wood pulp fibers. 
     
     
         18 . The paper product of  claim 14 , wherein the paper product has a Breaking Length of at least approximately 7.0 km. 
     
     
         19 . The paper product of  claim 14 , wherein the paper product has a Tensile Energy Absorption (TEA) of at least approximately 110 J/m 2 . 
     
     
         20 . The paper product of  claim 14 , wherein the paper product has a Tear Index of less than at least approximately 9.6 mN·m 2 /g, and wherein the paper product comprises approximately 0.8 percent starch, approximately 10 percent SEPF, and approximately 90 percent wood pulp fibers.