Improving Wet End Efficiency with the Latest Forming Fabric Technology Chad Martin Forming Product Business Leader Forming Global Innovation Leader
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.
Structured Yarn Technology 0.18 0.15 x 0.18 0.15 Area = πr 2 = 0.025 Area h w = 0.026* Area = πr 2 = 0.018 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
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
APPLICATION REGION: MACHINE: POSITION: GRADE: BASIS WEIGHT: SPEED: FURNISH: North America C-Wrap with TAD Outer Tissue 28 31 gsm 1220-1360 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.
Fiber Carry Back
Fiber Carry Back
APPLICATION REGION: MACHINE: POSITION: GRADE: BASIS WEIGHT: SPEED: FURNISH: North America C-Wrap with TAD Outer Tissue 28 31 gsm 1200-1400 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.
APPLICATION REGION: MACHINE: POSITION: GRADE: BASIS WEIGHT: SPEED: FURNISH: North America Solid C-Wrap Outer Tissue and Towel 15 23 gsm 1370-1675 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
APPLICATION REGION: North America MACHINE: Crescent Former POSITION: GRADE: BASIS WEIGHT: Forming Tissue/Towel 15 39 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).
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
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
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
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