Method for manufacturing an adhesive compound for use in the production of corrugated paperboard

1. A method of manufacturing an adhesive compound, the method comprising the steps of:

providing a first amount of water;

heating the water to a first temperature;

adding a rheology modifier to the heated water to create a heated solution, wherein the rheology modifier is a water-soluble polymer material;

adding a first starch to the heated solution;

adding a caustic to the heated solution;

mixing the heated solution for a first period of time to create a heated mixture;

adding a first borate to the heated mixture; and

mixing the heated mixture for a second period of time;

adding a second amount of water to the heated mixture, the second amount of water is from about 135% to about 150% of the first amount of water;

re-heating the heated mixture to a second temperature, wherein the second temperature is a range from about 90° F. to about 100° F.;

flushing the heated mixture with an amount of flush water, the amount of flush water is from about 14% to about 18% of the second amount of water;

adding a second borate, the second borate is from about 50% to about 100% of the amount of the first borate;

adding a second starch, the second starch is from about 450% to about 650% of the amount of the first starch; and

mixing the heated mixture for a third period of time.

2. The method of claim 1 , wherein the rheology modifier is from about 2.5 to about 6% solids by weight (% wt. solids) of the heated solution.

3. The method of claim 1 , wherein the first starch is from about 7.5 to about 12% wt. solids of the heated solution.

4. The method of claim 1 , wherein the caustic is from about 1 to about 4% wt. solids of the heated solution.

5. The method of claim 1 , wherein the first borate is from about 0.1 to about 1% wt. solids of the heated mixture prior to mixing the heated mixture for the second period of time.

6. The method of claim 1 , wherein the first time period is in a range from one minute to five minutes; and

wherein the first temperature is less than 120° F.

7. The method of claim 1 , wherein the first temperature is less than 120° F.

8. The method of claim 7 , wherein the first temperature is in a range from about 105° F. to about 115° F.

9. The method of claim 1 , wherein the rheology modifier is from about 2.5 to about 6% solids by weight (% wt. solids) of the heated solution;

wherein the starch is from about 7.5 to about 12% wt. solids of the heated solution;

wherein the caustic is from about 1 to about 4% wt. solids of the heated solution;

wherein the first borate is from about 0.1 to about 1% wt. solids of the heated mixture prior to mixing the heated mixture for the second period of time;

wherein the first time period is in a range from one minute to five minutes; and

wherein the first temperature is less than 120° F.

10. The method of claim 9 , wherein the second time period is from about 1 minute to about 3 minutes.

11. The method of claim 1 , wherein the third period of time is from about 0.5 minute to about 2 minutes.

12. The method of claim 1 , subsequent to the step of mixing the heated mixture for a third period of time, further comprising the steps of:

adding a biocide to the heated mixture;

adding a defoamer to the heated mixture;

adding a penetrating agent to the heated mixture; and

mixing the heated mixture for a fourth period of time.

13. The method of claim 12 , wherein the amount of biocide is from about 0.005% to about 0.25% solids by weight of the heated mixture.

14. The method of claim 12 , wherein the biocide has a mass and the defoamer has a mass which is from about 5% to about 10% of the biocide mass.

15. The method of claim 12 , wherein the biocide has a mass and the penetrating agent has a mass which is from about 25% to about 45% of the biocide mass.

16. The method of claim 12 , wherein the fourth period of time is from about 0.5 minute to about 2 minutes.

17. The method of claim 12 , subsequent to the step of mixing the heated mixture for a fourth period of time, further comprising the steps of:

mixing the heated mixture for a fifth period of time, wherein the fifth period of time is from about 1 minute to about 3 minutes, to create the adhesive compound.

18. A method of manufacturing an adhesive compound, the method comprising the steps of:

providing an amount of water contained within a source container;

heating the water to a first temperature;

adding a rheology modifier to the heated water to create a heated solution;

adding a starch to the heated solution;

mixing the heated solution for a first period of time to create a heated mixture;

adding a first borate to the heated mixture;

adding a biocide to the heated mixture;

adding a defoamer to the heated mixture;

adding a penetrating agent to the heated mixture; and

mixing the heated mixture for a second period of time to create the adhesive compound;

adding a second amount of water to the heated mixture, the second amount of water is from about 135% to about 150% of the first amount of water;

re-heating the heated mixture to a second temperature, wherein the second temperature is a range from about 90° F. to about 100° F.;

flushing the heating mixture with an amount of flush water, wherein the amount of flush water is from about 14% to about 18% of the second amount of water;

adding a second borate, the second borate is from about 50% to about 100% of the amount of the first borate;

adding a second starch, wherein the second starch is from about 450% to about 650% of the amount of the first starch; and

mixing the heated mixture for a third period of time.