Optimizing the mechanical properties of papers reinforced with refining and layer-by-layer treated recycled fibers using response surface methodology

Layer-by-layer (LbL) treated recycled fibers were investigated in mixtures with refined pulp relative to the mechanical properties of paper. The LbL treatments were conducted to assemble consecutive cationic and anionic starch layers on the fibers of old corrugated container (OCC) pulp. Fibers zeta potential was measured to examine the success of LbL treatment. Atomic force microscopy (AFM) and scanning electron microscopy (SEM) were used to reveal the differences between treated and untreated fibers surface and network. Subsequently, the LbL-treated fibers were added to the refined OCC pulps. Optimization of paper (60 ± 3 g m-2 basis weight) strength properties including: tensile index, Scott bond (internal bonding), and ring crush test (RCT) was carried out by response surface methodology (RSM). The meaningful change of zeta potential substantiated cationic/anionic starch layers construction. The AFM results showed that the surface of fibers were covered with starch, which was consistent with deposition of polyelectrolyte multi-layers (PEMs). The surfaces of the LbL-treated fibers were rough in comparison with untreated fibers. The optimization of mechanical parameters using RSM indicated that refining time significantly affected the paper's mechanical properties. The property values of 44.5 N.m/g tensile index, 149 J/m2 Scott bond, 32 mN RCT, and 245% strain at break were achieved at optimal conditions of 16 min refining time and the addition ratio of 17.6% LbL treated pulp respectively.