A sudden surge in the number of translucent and oval-shaped waxy spots caused a serious production loss of the papermaking process. The investigation of the spots revealed that the alkyl ketene dimer (AKD) sizing agent caused the waxy spot problem. A ultraviolet/visible (UV/vis) spectrometry method for the quantitative analysis of AKD was developed and used to reduce the waxy spot problem in paper products. The results showed that the method could be used to quantify AKD in both papermaking stock and white water. The major factors in the papermaking wet end that were associated with the waxy spot problem were evaluated, and practical approaches to solving the AKD retention problem and the waxy spot problem were proposed and implemented. The dosage of a retention aid was found to be the principal factor controlling AKD retention. However, varying the retention aid dosage resulted in the deterioration of the paper formation; therefore, this was not a suitable solution to the waxy spot problem. The type of fixing agent and AKD used was found to be the secondary factor affecting the AKD retention and papermaking system cleanliness. Mill trials were conducted on a paper machine to examine the effects of different fixing agents and AKD types on AKD retention and the waxy spot count at the reel. This approach identified a combination of fixing agent and AKD type that substantially improved AKD retention and reduced the formation of translucent waxy spots in the resulting paper products.
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