Alkyl Ketene Dimer (AKD) wax is a highly effective sizing agent for modern papermaking, offering superior water resistance and enhanced paper properties. However, like any chemical process, achieving optimal results with AKD can sometimes involve overcoming specific challenges. As a dedicated manufacturer and supplier of AKD wax, we are committed to helping paper mills achieve seamless integration and consistent performance. This article addresses common issues encountered with AKD sizing and provides practical troubleshooting solutions.

Common Challenges in AKD Sizing:

  1. Inadequate Sizing (Low Water Resistance): This is perhaps the most frequent issue, manifesting as poor performance in water resistance tests or increased ink feathering.
    • Potential Causes: Insufficient AKD dosage, poor retention of AKD on fibers, incomplete curing (esterification), incorrect pH, or unstable AKD emulsion.
    • Troubleshooting:
      • Verify Dosage: Ensure the AKD dosage aligns with the required sizing level and paper grade.
      • Optimize Retention: Review the use and dosage of retention aids, which are crucial for anchoring AKD to fibers.
      • Check Curing Conditions: The esterification reaction requires adequate heat. Ensure sufficient drying temperature and time in the paper machine’s drying section.
      • Monitor pH: Confirm the process pH is within the optimal range for AKD (neutral to slightly alkaline).
      • Emulsion Stability: An unstable emulsion can lead to uneven application, impacting sizing.
  2. Poor AKD Emulsion Stability: An unstable emulsion can lead to streaky sizing, deposits on machinery, and reduced efficiency.
    • Potential Causes: Improper preparation of the AKD emulsion, incorrect emulsifier selection or dosage, contamination, or improper storage conditions.
    • Troubleshooting:
      • Review Emulsification Process: Ensure correct temperatures, mixing speeds, and reagent addition sequences are followed during emulsion preparation.
      • Select Appropriate Emulsifiers: Work with your supplier to ensure you are using compatible and effective emulsifying agents tailored for AKD.
      • Check Storage: Store AKD and its emulsions under recommended conditions to maintain stability.
  3. Deposits on Paper Machine Equipment: Unreacted AKD or unstable emulsion components can adhere to machine parts, causing operational issues and impacting paper quality.
    • Potential Causes: Over-dosage of AKD, poor emulsion stability, or interactions with other chemicals in the system.
    • Troubleshooting:
      • Optimize Dosage: Reduce AKD dosage if it’s found to be excessive.
      • Improve Emulsion Stability: Address issues contributing to emulsion instability.
      • Chemical Compatibility: Review the compatibility of AKD with all other chemicals in the wet end.
      • Regular Cleaning: Implement a consistent cleaning schedule for machine components.
  4. Variability in Paper Quality: Inconsistent sizing or strength can occur due to fluctuations in the papermaking process.
    • Potential Causes: Variations in AKD dosage, inconsistent pulp properties, or fluctuating machine operating conditions (pH, temperature).
    • Troubleshooting:
      • Standardize Application: Implement strict controls on AKD dosing and application procedures.
      • Monitor Pulp: Ensure consistent pulp quality and preparation.
      • Process Control: Maintain stable machine conditions, especially pH and drying temperatures.
  5. Foaming Issues: While less common with AKD, certain emulsifiers or process conditions can sometimes lead to foaming.
    • Troubleshooting: Adjust AKD and emulsifier levels, or consider using a suitable defoamer.

Our Commitment as Your AKD Wax Supplier

As a dedicated manufacturer and supplier, we aim to provide not only high-quality AKD wax but also the technical expertise to help you overcome any operational challenges. We encourage you to buy AKD wax from us for consistent product performance and reliable support. By understanding these common issues and proactively implementing the troubleshooting steps, paper manufacturers can ensure the efficient and effective use of AKD wax, leading to superior paper quality and production efficiency. Don’t hesitate to contact our technical team for personalized assistance with your AKD sizing process.