Student presentations
Spring 2026
Session Chair: Drs. James Springstead and Mert Atilhan
Room D-109
Design of Degasser System for Improved Transition Between Coatings in Paper Production
8:30 to 8:55 a.m.
Team Members:
Yossary Mercado
Chrys Pestana
Jenna Ridley
Ilma Sang
Sponsors:
Brad Fadden, B.S.’98, Graphic Packaging International
Gabby Struut, Graphic Packaging International
Faculty Advisor:
Dr. James Springstead
In collaboration with Graphic Packaging International, this Senior Design initiative optimizes the curtain coater supply system, a critical loop of the paper making process for applying coating to the sheet. To address the system’s complexity, the project is divided between two student teams; our group focuses exclusively on the downstream of the Top Layer supply line, encompassing high-vacuum Deaeration units and Machine Tanks. The primary challenge is the product transition between paper grades, which currently results in material intermixing and significant waste, due to variation in coating formulation for specialty grades. Through leveraging historical process data from the plant’s distributed control system, our team has modeled the fluid dynamics of these transitions to identify efficiency bottlenecks. The proposed solution involves a strategic process redesign utilizing advanced valve sequencing to achieve "plug flow" behavior. This optimization seeks to drastically reduce the volume of mixed coating generated, ensuring faster, cleaner, and more sustainable production changeovers.
Waste Activated Sludge Drying Improvements
9 to 9:25 a.m.
Team Members:
Donovan Estes
Raquel Matos Ogando
Luke Suman
Sponsors:
Nicholas Corey, USG Otsego
Connor Dolan, USG Otsego
Eric Bock, B.S.E.’13, USG Otsego
Faculty Advisor:
Dr. James Springstead
USG Otsego Paper, a recycled fiber mill, is pursuing an ambitious sustainability goal of achieving zero waste to landfill by 2030. A significant barrier to this objective is the large volume of waste activated sludge (WAS) produced by the mill wastewater treatment system. This sludge, composed primarily of microbial biomass, is currently disposed to landfill. Reducing its water content could create opportunities for use, avoiding disposal. The mill currently relies on an aging sludge press for dewatering; however, the reduced water content remains insufficient for alternative uses. Additionally, the microbial nature of WAS presents inherent challenges, as microbial cells particularly retain significant amounts of water. This project evaluates the feasibility of an enhanced dewatering system. It proposes potential equipment upgrades, process layout and integration considerations and preliminary project financials for the Otsego facility.
Mineral Addition to Molded Fiber—Preserving strength and Reducing Energy Demands
9:30 to 9:55 a.m.
Team Members:
Ryan Ball
Aidan Bowie
Ashley Randall
Sponsors:
Leslie McLain, Artemyn
Gregg Reed, Artemyn
Heather Starkey, Primient
Meggan Hostetler, Primient
Jeremy Iwanski, Primient
Faculty Advisors:
Dr. James Springstead
Dr. Jason Wang
Filler has been proven to be a beneficial additive in papermaking. Previous data supports that the addition of mineral fillers to thermoformed molded fiber applications reduced sheet moisture by roughly 11.5% which reduced drying energy by approximately five to $15 per ton. However, data showed a decrease in strength properties despite cost savings. The goal of this year’s project is to retain strength at higher ash content in the composition of thermoformed molded fiber application using an inline dilution system that will disperse a mixture of starch and filler material. By using starch the team expects to lessen the effects of filler material on fiber bonding while also maintaining reduced energy costs. The design team must select the most optimal conditions based on strength, cost, energy savings and productivity.
Maximizing Strength Additive Efficiency Through Alternative Application Strategies
10 to 10:25 a.m.
Team Members:
Kofi Barima
Connor Johnson
Aimee Lambert
Kaitlyn Zaborowski
Sponsors:
Stephen Bussa, B.S.E.’19, Axchem
Rich Waite, B.S.E.’19, Axchem
James Owens, Axchem
Mark Zempel, B.S.E.’92, Axchem
Faculty Advisors:
Dr. Mert Atilhan
Dr. Jason Wang
The maximization of functional additive efficiency in papermaking is a crucial component of improving and maintaining machine runnability, finished product quality, and ultimate mill profitability. Among these chemistries are strength additives, which are functional additives used to improve dry and wet sheet strength in ways that simply cannot be achieved through pulp fibers alone. Traditional means of strength generation come primarily from mechanical refining, which works to increase the potential for fiber-to-fiber bonding through fibrillation. Despite its positive impact on strength generation, mechanical refining is linked to fines generation and significant losses in drainage potential, harming sheet formation and increasing energy demands downstream. To alleviate this, functional chemistries aimed at aiding strength generation are often added to stock approach systems and the wet end of the paper machine. This project will work to challenge the industry standard regarding current strength additive strategies by exploring alternative configurations of strength additive applications, pushing the boundaries of modern papermaking and delivering innovative solutions for better, faster and cheaper means of manufacturing paper.
Optimization of Recovered Soda Ash in Semi-Chemical Pulping
10:30 to 10:55 a.m.
Team Members:
Seth June
John McClelland
Brady Nason
Sponsors:
Emma Willkinson, PCA Filer City
Michael Thompson, B.S.E.’93, PCA Filer City
Carl Brown, B.S.E.’00, PCA Filer City
Faculty Advisors:
Dr. James Springstead
Matt Stoops
The objective of this project is to determine the impact of fresh soda ash versus recovered green liquor on pulp quality. Our industry sponsor, PCA Filer City, is a fully integrated paper mill which produces several different grades of containerboard. Their pulping facility uses a semi-chemical process with sodium carbonate, known commonly as soda ash, for the primary cooking chemical. The soda ash is washed from the pulp as black liquor and recovered as pellets, via a Copeland reactor. This recovered soda ash is clarified and mixed with fresh ash to make the white liquor used in the digester process. Our plan to complete this project is to create a variety of pulps with varying fresh-to-recycled soda ash ratios and form handsheets for physical property testing. As the finished product is containerboard, optical properties are not of high interest, so testing will primarily concern strength properties and chemical makeup. Based on the results from strength testing, an optimal ratio will be recommended.
Evaluation of Wet-End Additives to Eliminate Starch Spray in Multi-Ply Coated Recycled Board Production
11 to 11:25 a.m.
Team Members:
Noah Lawson
Nayab Tufail
Collins Wekesa
Sponsors:
Ryan Glaser, Ecolab
David Jordan, Ecolab
Jake Carpenter, Ecolab
Gabby Stuut, Graphic Packaging International
Samantha Schoenfelder, M.S.’17, Graphic Packaging International
Geoff Mallett, B.S.E.’19, Graphic Packaging International
Faculty Advisors:
Dr. Mert Atilhan
Dr. Jason Wang
The project is conducted in collaboration with Graphic Packaging International (GPI) and Nalco Water (an Ecolab company). It evaluates different wet-end chemical additives as an alternative to starch spray application for multi-ply coated recycled paper board production. The feasibility of eliminating the starch spray system is determined while maintaining critical dry strength properties of the paperboard. This was achieved through laboratory testing and scaled-up process analyses used to identify the chemical additive combinations that maintain the required dry strength of the paperboard. Data driven recommendations for chemical usage and implementation cost are evaluated to assess overall viability. The outcome of this project is a technical and economic recommendation regarding removal of the starch spray application without compromising paper sheet strength, machine performance or production reliability.
Sludge Stream Reclamation System Design
11:30 to 11:55 p.m.
Team Members:
Allen Crowe
Hamza Hossain
Miles Miller
Rachel Musser
Sponsor:
Frank Delgrego, PaperWorks Industries
Faculty Advisor:
Dr. James Springstead
In this project we evaluate the technical and economic feasibility of recovering usable paper fibers from the sludge stream generated at a recycled paper mill and reintroducing them into the existing papermaking process. The sludge produced through PaperWorks Industries' pulping and wastewater clarification at the mill is currently disposed through landfill or agricultural applications. The sludge is believed to contain recoverable fibers that can be reused for papermaking. To verify these assumptions, the project includes laboratory testing, process evaluation and economic analysis. Laboratory testing focuses on characterizing the sludge by determining solids content, ash content, fiber quality and other relevant properties to quantify fiber quantity and usability. Based on laboratory results, a reclamation system proposed by our sponsor will be further evaluated using Aspen Software to assess real world applicability. The project also evaluates the economic feasibility of implementing a fiber reclamation system by considering capital and operating costs, savings associated with reduced fiber purchases, and savings from current sludge disposal methods. The results of this project will inform the decision of whether fiber recovery from the sludge stream is technically and economically justified.
Extraction of Carbon Dioxide from the Atmosphere
1:30 to 1:55 p.m.
Team Member:
Ibrahim Alwaheibi
Faculty Advisor:
Dr. James Springstead
The rise in atmospheric carbon dioxide (CO2) from human activities is a major contributor to climate change. Carbon capture and sequestration (CCS), combined with energy efficiency and low-carbon energy sources, constitute an effective approach to reducing CO2 emissions. This senior project examines carbon capture from industrial point sources using absorbent-based technology. CO2 is captured from flue gas streams using a chemical solvent, followed by regeneration and compression of the captured CO2 for sequestration. In this study I evaluate gas liquid contact efficiency, energy demand, solvent performance, and system integration. Mass and energy balances are conducted, and capital and operating costs are estimated using standard chemical engineering methods. Results indicate that point source carbon capture is technically feasible and can significantly reduce industrial CO2 emissions when integrated with reliable sequestration methods.
Development of a Grease Resistant Barrier for Food Industry Applications
2 to 2:25 p.m.
Team Members:
Ashley David
Sydney Moranko
Mira Marino
Abbygale Ruggiero
Sponsor:
Brian Scheller, B.S.’08, Billerud
Faculty Advisors:
Dr. Mert Atilhan
Dr. Jason Wang
The food industry is facing increasing pressure to develop grease-resistant barrier coatings that meet both performance requirements and sustainability goals. This project aims to evaluate and develop alternative coating formulations for paper food products that will provide effective grease resistance while reducing environmental impact. Our team will conduct a comprehensive review of potential barrier materials and identify promising candidates based on performance benchmarks, sustainability metrics, and industry standards. Laboratory scale coating formulations will be developed and tested to determine the coating levels required to achieve target grease resistance. Performance testing will be guided by established evaluation methods and available literature. As part of the engineering design component, the team will work to optimize a process in the barrier coating system. This process design will integrate a full financial analysis to compare the proposed coatings to current industrial standard coatings. Economic viability will be evaluated using metrics such as return on investment, payback period, and internal rate of return, alongside sustainability considerations. The results of this study and financial run through will help determine whether novel barrier coatings can provide a functional and economically feasible alternative for food packaging applications.
Reduction of Environmental Footprint through On-Site Anaerobic BOD Treatment
2:30 to 2:55 p.m.
Team Members:
Caleb Breining
Ahmad Fariz Ikmal Hisham
Tajanae Lewis
Sponsors:
Brian Traylor, APS Grupa
Rusty Napier, APS Grupa
Faculty Advisor:
Dr. Mert Atilhan
APS Grupa is an industrial processor of functionalized soy proteins that are used in the paper and paperboard industry, as well as other markets serving adhesive applications. One output of our manufacturing process is a high BOD whey waste stream that is currently sent to the Chicago MWRD for treatment. This treatment is costly and significantly impacts our environmental footprint. To help close this environmental loop and reduce treatment expenses, we are looking to evaluate and develop an anaerobic treatment process that will bring our BOD discharge to nominal levels. For a Senior Project, students will research, experiment, and evaluate potential system designs to identify which bacterial strain(s) would provide the optimal balance of treatment efficiency and capital costs. The students will research multiple options of bacterial strains, experiment with each one, and then present the data along with their cost analysis for each strain to determine the best approach. The students will also have access to our extended team for additional process and project engineering support, including financial modeling and business-case development.
Design of Heat Exchanger, Feed and Machine Tanks for Improved Transition Between Coatings in Paper Production
3 to 3:25 p.m.
Team Members:
Morgan Herremans
Carson Klima
Nicole Rodriguez
Oliver Wasson
Sponsors:
Brad Fadden, B.S.’98, Graphic Packaging International
Gabby Struut, Graphic Packaging International
Faculty Advisor:
Dr. James Springstead
Graphic Packaging in Kalamazoo produces paperboard products with varying top and bottom coatings. The coated paperboard is used to create structurally sound, yet visually appealing products through printing. Graphic packaging is currently able to transition from its commodity coating to a specialty coating in six to eight hours. This results in wasted coating, lengths of the paper sheet that can’t be sold at the same price as the specialty grade paper and reduced machine productivity. It should also be noted that the formula pricing of the specialty coating is two to three times more expensive than the generic formula. As the company begins investing in more specialty coatings, it is vital to minimize waste and reduce the cost per ton. Graphic Packaging currently has two top, two bottom and a swing degassing system for the K2 curtain coater. The degassing system is utilized to eliminate air within the coating and maintain a well-mixed state to be applied to a sheet smoothly and at exceptional speeds. A team is tasked with adding a sixth degassing system, focusing on the heat exchanger, feed tank, machine tank and two screw pumps. This team will work with another team to design the full degassing system. This system has the intent to eliminate air in the coating mixture while decreasing the transition time to specialty coatings. The project aims to maximize production efficiency and support Graphic Packaging's growing use of specialty coatings.
Coarse Rejects Shredding for Tailbox Stream Sustainability Improvements
3:30 to 3:55 p.m.
Team Members:
Sam Bet
Jack Liu
Colin Lauraine
Sponsors:
Nicholas Corey, USG Otsego
Connor Dolan, USG Otsego
Eric Bock, B.S.E.’13, USG Otsego
Faculty Advisor:
Dr. James Springstead
USG Otsego, a 100% recycled-fiber mill producing gypsum-grade wall board, generates significant coarse rejects in its Tailbox stream, currently landfilled at high cost and conflicting with Knauf’s 2030 zero-waste-to-landfill goal. The team is investigating a Kadant-Babbini single-shaft shredder and an aero-magnetic metal separator to process these rejects. The system will reduce size, separate recoverable metals for recycling revenue and prepare non-metallic fractions as potential refuse-derived fuel, minimizing landfill use while maintaining mill operations. Deliverables include equipment identification and layout in the Tailbox room, reject stream composition estimates, operational procedures and economic analysis (disposal savings, metal revenue, payback period, IRR). Preliminary market survey and research are complete, with vendor confirmation and sponsor data integration ongoing. This solution promotes circular economic practices and directly advances the mill’s sustainability objectives.
Investigating the Cost and Efficiency of Two Chemical Pathways to Produce the Plant-based Coagulants
4 to 4:25 p.m.
Team Members:
Li En Foo
Taylor Nixon
Ted Sherer
Faculty Advisor:
Dr. Priyanka Sharma
Plant-based coagulants are promising sustainable alternatives for water treatment due to their biodegradability, low toxicity, and reduced risk of secondary pollution. Unlike conventional inorganic coagulants, they generate less sludge and avoid secondary contamination in the environment. This project examines two chemical modification strategies for producing cationic cellulose coagulants. The first involves direct amination of cellulose using CHPTAC, while the second employs periodate-oxidized dialdehyde cellulose, which enables reductive amination through reactive aldehyde groups. These approaches are expected to yield materials with differing charges, surface functionalities, and structural properties that may influence coagulation performance. The study evaluates the technical and economic feasibility of both routes by comparing reaction conditions, reagent use, yields, waste generation, and energy requirements. Material and energy balances are developed to support process design, scale-up, and selection of the most cost-effective and environmentally viable production pathway.