Research and development for the pulp and paper industry involves the use of sound, contemporary science to solve complex technical problems.  This approach provides two distinct results.  The first is the refinement of existing products to meet immediate customer needs.  An example of this is finding alternative sources of surfactants for felt conditioning and cleaning products that are more cost effective and environmentally acceptable.  The second outcome is the discovery and introduction of new products with significantly different properties and benefits.  An example of this would be the development of new strength additives that enable papermakers to reduce the level of fiber in the sheet while still meeting all performance requirements.
 
Formulation and development of new products requires a balanced approach among three critical areas:

Proprietary test methods
Fundamental mechanistic models
Application technology

Proprietary Test Methods

Proprietary test methods are used to simulate the chemistry, physics, or microbiology of pulping and papermaking systems and to develop products, mechanistic models, or product application guidelines.  These methods are valuable because they can accelerate the development of novel technology and contribute to the creation of an enhanced technology knowledge base.

Fundamental Mechanistic Models

The development of fundamental mechanistic models, which accelerate new product development, is critical to the research and discovery effort.  For example, five years of phenomenological research failed to identify more effective products for organic contaminant control.  Subsequently, fundamental surface chemistry techniques and experiments were employed that led to a working mechanistic model of detackification.  This model was used in turn to structure a search for detackifiers.  It resulted in the development of a new, commercially successful and patented product in less than eight months.

A second example of mechanistic models is the use of finite element analysis.  This paper physics technique has been applied to packaging containers to predict their performance before the paper machine trial is run, before the paper is converted into containers, and before the containers are ever tested in the field.  This technology has made rapid progress within Hercules and is now being used routinely for the evaluation of new sizing and strength technologies in relevant grades.

Application Technology

A key component of product development is the investigation and identification of application technology through experiments in the laboratory and during trials on commercial paper machines.  These provide application guidelines that are critical for the successful deployment of any new technology.  Parameters that are considered include product feed points, optimum process water conditions, and product-process interactions.  For example, the chemical stability of a surface-active biopolymer recently identified as a novel contaminant control agent has been demonstrated under alkaline conditions.  This information was needed to reach a decision concerning the use of polymer in pulp mills and bleach plants.

Research projects are undertaken with the expectation that economic value will be the outcome.  Discovery is not an end in itself.  Criteria for the initiation of investigations and product development projects are based on customer needs analysis and the Research and Development group's experience in translating new technologies into practical applications for improving pulp and paper operations.  Core Competencies include synthetic and physical organic chemistry, surface science, colloid science, polymer chemistry, as well as microbiological science.