Improving Wet End Efficiency with the Latest Forming Fabric Technology

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2 Improving Wet End Efficiency with the Latest Forming Fabric Technology Chad Martin Forming Product Business Leader Forming Global Innovation Leader

3 MD Yarn Evolution Traditional (round) MD yarn technology Support Drainage Life & Stability Structured MD yarn technology Increased cross sectional area for improved stability Low caliper and void volume: improve applied vacuum efficiency (sheet solids!) and fabric cleanliness Attain higher machine speeds, runnability and reduced drive loads Structured MD yarns on the bottom for maximum stability in a fine SSB design.

4 Structured Yarn Technology x Area = πr 2 = Area h w = 0.026* Area = πr 2 = Benefits: The rectangular like cross section of the structured yarn achieves the low caliper of smaller yarns while offering greater cross-sectional area than round yarns of the same width. When incorporated into forming fabric structures, this translates to: Lower caliper & thus lower void volume Better dimension stability Potential for more open top surface * Area is slightly less due to rounded corners

5 Application Guide Line 6-shed Machine Side for Maximum Life Crescent Formers Fourdrinier C-wrap Outer Positions 4-shed Machine Side for Best Drainage and Low Water Carry Crescent Formers S-Wrap Outer Solid C-Wrap Outer C-Wrap TAD Inner Suction C-Wrap Inner & Outer PW PS 6-Shed MS PW PS 4-Shed MS

6 APPLICATION REGION: MACHINE: POSITION: GRADE: BASIS WEIGHT: SPEED: FURNISH: North America C-Wrap with TAD Outer Tissue gsm m/min 100% Virgin 6-shed Machine Side Version OBJECTIVES: Primary: Reduce the amount of wet end breaks Secondary: Reduce fiber carryback numbers. Tertiary: Increase life RESULTS: Carryback before showering reduced from.0904 g/m2 to.058 g/m2 resulting in 36% reduction. Carryback after showering reduced from.0382 g/m2 to.0176 g/m2 resulting in 54% reduction. Previous life average was 100 days with 145 day longest run. T-Star ran 167 days with potential to run 300 plus days.

7 Fiber Carry Back

8 Fiber Carry Back

9 APPLICATION REGION: MACHINE: POSITION: GRADE: BASIS WEIGHT: SPEED: FURNISH: North America C-Wrap with TAD Outer Tissue gsm m/min 100% Virgin 4-shed Machine Side Version OBJECTIVES: Primary: Reduce energy cost Secondary: Reduce fiber carryback and bleed thru Tertiary: Improve Formation RESULTS: Dewatering Box Vacuum was reduced by 20% at equal machine speed. Former Section Load was reduced. Improved Formation The Headbox Slice was opened significantly resulting in a 30% increase in water volume while maintaining machine speed.

10 APPLICATION REGION: MACHINE: POSITION: GRADE: BASIS WEIGHT: SPEED: FURNISH: North America Solid C-Wrap Outer Tissue and Towel gsm mpm 80% Virgin 6-shed Machine Side Version OBJECTIVES: Improve Formation, Reduce Fiber Carryback, and Improve Former Cleanliness RESULTS: VALUE Approximately $500,000-5 Ton/Day production increase based on a reduction in lost time as well improved formation and drainage. Formation Improved drainage allowed for a more open slice position and jet impingement change resulting in improved formation. Drainage improvement resulted in an added benefit of a 30 mpm average machine speed increase. Fiber Carryback 50% improvement versus previous supplier Former Cleanliness reduction in time taken for Former wash-up because fabric is easier to keep clean Awarded Single Source Supplier for this position

11 APPLICATION REGION: North America MACHINE: Crescent Former POSITION: GRADE: BASIS WEIGHT: Forming Tissue/Towel gsm Breast Roll Headbox SPEED: 1830 mpm FURNISH: Virgin HWK & SWK 6-shed Machine Side Version Trim System Forming Roll Forming Wire Breaker Roll OBJECTIVES: Provide a design to work with the Trim System to reduce down time by eliminating the need to change fabrics based on trim width Improve Machine Cleanliness Increase fabric life RESULTS / VALUE $180,000 savings for reduced downtime to change fabrics. $15,000 savings for reduced set-up time at the winder. $28,000 savings due to life increase (150 days).

12 APPLICATION REGION: Latin America MACHINE: Crescent Former POSITION: GRADE: BASIS WEIGHT: Forming Tissue 13.5 gsm Breast Roll Headbox SPEED: 1950 mpm FURNISH: Recycle 6-shed Machine Side Version Forming Roll Forming Wire Breaker Roll OBJECTIVES: Equal or better target life of 150 days Maintain trim bead width stability on this tight tolerance machine Paper width at reel was critical RESULTS T-Star obtained a life record of 206 days; fabric was damaged off. Sheet width remained stable throughout fabric life Improve paper formation Improve moisture profile

13 Structured Yarn Results Low void volume = clean running former = less breaks = Increase machine efficiency High fiber support = Increase mechanical retention = Improved formation and low fiber carry back Increase drainage capacity = Increased dryness into Press or TAD section Excellent dimensional stability (length and width) Improved CD sheet profiles

14 Structured Yarn Application Summary Machine types: Publication grade machines Tissue C-Wrap, Suction C-Wrap Crescent Formers Fourdriniers Target paper grades: Publication Tissue and Towel Order and installations 1200 orders in 25 countries 165 on Tissue machines 660 installations 85 on Tissue machines

15 S t r u c t u r e d P r o d u c t s f o r M a x i m u m R e s u l t s D e s i g n s A v a i l a b l e f o r E v e r y T i s s u e A p p l i c a t i o n