SYSTEMS AND METHODS FOR PRODUCTION OF STARCH-LOADED FIBRILLATED FIBERS

1 . A method of making a pulp composition, the method comprising:

mixing together a starch and fibrillated fibers to produce a starch/fibrillated fibers mixture; and

mixing the starch/fibrillated fibers mixture into wood pulp fibers to produce the pulp composition.

2 . The method of claim 1 , wherein the wood pulp fibers comprise one or more of hardwood pulp fibers, softwood pulp fibers, non-wood pulp, recycled pulp fibers, or combinations thereof.

3 . The method of claim 2 , further comprising:

depositing the pulp composition onto a web to form a substrate;

at least partially dewatering the substrate; and

drying the substrate to form a paper product.

4 . The method of claim 3 , wherein the fibrillated fibers comprise surface enhanced pulp fibers (SEPF).

5 . The method of claim 4 , wherein the paper product comprises approximately 0.1 to 2.5 weight percent starch, approximately 2 to 20 weight percent SEPF, and approximately 83 to 97 weight percent wood pulp fibers.

6 . The method of claim 5 , wherein the paper product comprises approximately 0.4 to 2.0 weight percent starch, approximately 3 to 17 weight percent SEPF, and approximately 83 to 97 weight percent wood pulp fibers.

7 . The method of claim 6 , wherein the paper product has a Breaking Length of at least approximately 7.0 km.

8 . The method of claim 7 , wherein the paper product has a Tensile Energy Absorption (TEA) of at least approximately 110 J/m 2 .

9 . The method of claim 8 , wherein the paper product has a Tear Index of less than at least approximately 9.6 mN·m 2 /g.

10 . The method of claim 4 , wherein the paper product comprises approximately 0.8 percent starch, approximately 10 percent SEPF, and approximately 90 percent wood pulp fibers.

11 . The method of claim 10 , wherein the paper product has a Breaking Length of at least approximately 7.0 km.

12 . The method of claim 11 , wherein the paper product has a Tensile Energy Absorption (TEA) of at least approximately 106 J/m 2 .

13 . A method of making a paper product, the method comprising:

mixing together a starch and fibrillated fibers to produce a starch/fibrillated fibers mixture;

mixing the starch/fibrillated fibers mixture into wood pulp fibers to produce a pulp composition;

depositing the pulp composition onto a web to form a substrate;

at least partially dewatering the substrate; and

drying the substrate to form the paper product, wherein the paper product has an increased Breaking Length compared to a First Comparative Paper Product.

14 . A paper product comprising:

a starch in a first amount in the range of approximately 0.1 to 2.5 weight percent;

fibrillated fibers in a second amount in the range of approximately 2 to 20 weight percent; and

wood pulp fibers in a third amount in the range of approximately 83 to 97 weight percent,

wherein the paper product has a lower amount of the starch compared to a Second Comparative Paper Product; and

wherein the paper product maintains a Breaking Length within the range of approximately 10 percent compared to a Second Comparative Paper Product.

15 . The paper product of claim 14 , wherein the paper produce maintains a Breaking Length within the range of approximately 2 percent compared to a Second Comparative Paper Product.

16 . The paper product of claim 14 , wherein the paper product comprises approximately 0.1 to 2.5 weight percent starch, approximately 2 to 20 weight percent SEPF, and approximately 83 to 97 weight percent wood pulp fibers.

17 . The paper product of claim 16 , wherein the paper product comprises approximately 0.4 to 2.0 weight percent starch, approximately 3 to 17 weight percent SEPF, and approximately 83 to 97 weight percent wood pulp fibers.

18 . The paper product of claim 14 , wherein the paper product has a Breaking Length of at least approximately 7.0 km.

19 . The paper product of claim 14 , wherein the paper product has a Tensile Energy Absorption (TEA) of at least approximately 110 J/m 2 .

20 . The paper product of claim 14 , wherein the paper product has a Tear Index of less than at least approximately 9.6 mN·m 2 /g, and wherein the paper product comprises approximately 0.8 percent starch, approximately 10 percent SEPF, and approximately 90 percent wood pulp fibers.