Tissue World 2009 Final Asten Johnson
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Transcript of Tissue World 2009 Final Asten Johnson
Forming Fabric Application
for Tissue MakingBruce W Janda, Global Innovation Leader
Jean-François Landry, VP Sales & Marketing - Europe
March 24th, 2009
12/11/09 - Slide 2
Strakonice (Forming)Eupen (TAD)
11 Manufacturing Sites
5 Countries
+ =
12/11/09 - Slide 3
FabricSelection
OperationFurnish
Key to Success Engineered Approach
Angle to Fabric for the Chisel Shower
•Angling 15o Against the Direction of Fabric Travel is Effective for Face Side High Pressure Showers
15o
Fabr ic Travel • Sheetside application
• 1750 kpa max
• 7.5-10cm from fabric
• Angle increases effectiveness
HPN Shower Location
HPFN Shower
Drainage Pressure is defined as P=T/R
FIBER LENGTH ANALYSIS
0
200
400
600
800
1000
1200
1400
1600
1800
2000
0.000 0.500 1.000 1.500 2.000 2.500 3.000
Fiber Length (mm)
Nu
mb
er
of
fib
ers
STONE [CANADA] INC.
Stone Container Corp.
MILL AVRG L.W. W.W. 0.4 0.2STNRPQ-01 0.64 1.61 2.4 57.9 41.9 STHOLA-05 0.63 2.56 3.5 74.3 70.7
KajaaniFiber Length
Analyzer
12/11/09 - Slide 4
12/11/09 - Slide 5
InTegra®-T forming fabricPatent # US 5826627 EP #794283
12/11/09 - Slide 6
InTegra®T
Engineered Triple Layer Forming Fabrics for Tissue and Towel ing Util izing Intr ins ic Weft Design. Patent # US 5826627 EP #794283
•Excellent Drainage and Formation Characteristics: Ability to increase headbox dilution delivers improvements in formation and production/speed increases.
•Easy to Clean: Straight through drainage holes allow for efficient showering.
•Reduced CD Basis Weight and Moisture Variability: Delivers flat CD basis weight profiles even on the new high-flow headbox designs.
•Excellent Width Stability: Fabric is very width stable leading to consistent Reel widths on Crescent Formers.
•Improved Energy Efficiency: Improvements in drainage and formation allow for reduced drying energy use.
•Long Life Potential from Fabric Durability and Wear Volume: Record Life Achieved on many applications.
•Increased Retention. Retention increases can allow for strength chemical reductions, fiber substitutions and/or refining reductions.
12/11/09 - Slide 7
Stiffer fabric means better profi le!
Stiffness (in grm)
0
2
4
6
8
10
1 2 3 4
CMD
MD
SingleLayer
ES DoubleLayer
Std TripleLayer
InTegraT
FABRIC STIFFNESSStiffness (in gr.)
12/11/09 - Slide 8
Stiffer fabric means better profi le!
12/11/09 - Slide 9
Better profi le means uniform sheet!
12/11/09 - Slide 10
Crescent former experience
Speed:2,111 mpmBW: 15-17 GSMEdge +/- 3 mm.
Life: over 90 days
12/11/09 - Slide 11
InTegra® T sets Machine Speed Record on World’s Largest Crescent Former
Results:• Increased drainage allows machine to establish new speed record of
1844 mpm (old record 1828 mpm)• Fabric width very stable leading to improved machine efficiency
during break in period • Fiber carry back reduced• Cleaner running fabric from improved showering effectiveness• Excellent sheet edge from CF trim beads
inFO
RM
atio
n CF Tissue MachineForming PositionVirgin Bath TissueSpeed: 1844 mpm
Object ive:• Increase Formation and Drainage• Improve Fabric Width Stabil i ty • Maintain product quality , runnabil i ty
12/11/09 - Slide 12
InTegra® T Delivers Cost Savings on Crescent Former
Results:• Improved drainage and formation• Allowed increased secondary fiber use with equal tissue quality• Doubled forming fabric life by eliminating fabric delamination and
seam marking• Increased fabric width stability• Reduced variation in basis weight profile by 15%• Reduced variation in moisture profile by 3%
inFO
RM
atio
nCF Tissue MachineForming PositionVirgin/Recycled Bath TissueSpeed: 1737 mpm
Object ive:• Increase Fabr ic Life• Eliminate fabr ic de lamination• Eliminate Seam Marking Issue• Maintain product qual ity , runnabi l i ty
Total Savings: €900,000/yr
12/11/09 - Slide 13
InTegra® T Delivers Increased Machine Efficiency / Profit
Results:• Excellent machine runnabi l ity on ful l grade mix• Formation and drainage improved• Breaks reduced from 10 to 5 per day due to increased c leanl iness of
Outer sect ion• Fiber carry back reduced 30%• Increased machine speed 90 MPM on 22.6 GSM Towel• Production increased by 12 tons per day on Towel• Fabric l ife increased from 120 days to 150 days
inFO
RM
atio
nSuction C-Wrap Wet Crepe MachineOuter Forming PositionMaking 22.6 GSM Recycled TowelSpeed: 1219 mpm
Object ives:•Improve Outer Sect ion Cleanl iness•Increase Machine Speed•Increase Machine Profitabil ity•Increase Fabric Life
Annual Machine Profit Increase: €1,460,000
12/11/09 - Slide 14
InTegra T Reduces Energy Costs
Results :• Reduced TAD dryer temperature to achieve target reel
moisture• Energy savings exceeded €350,000/yr• Increased fabric stability• Eliminated fabric delamination• Improved machine cleanliness
inFO
RM
atio
nTAD Tissue MachineForming PositionMaking Virgin Bath TissueSpeed: 1143 mpm
Object ive:• Reduce energy use• Eliminate fabr ic de lamination• Maintain product qual ity , runnabi l i ty
Total Savings: €350,000/yr +
12/11/09 - Slide 15
InTegra®T Product LineEngineered Triple Layer Forming Fabrics for Tissue and Toweling Util izing Intrinsic Weft Design.
Patent # US 5826627 EP #794283
Fabric Caliper (‘.000”)
FS
I
140 -
150 -
160 -
170 -
180 -
.020 .025 .030
TSFT
AP Range: 400-570 cfm
Future direction•replace 1-2 layers•backing positions•SBR formers•reduce water carry•improved CD profiles•increase solids to TAD
12/11/09 - Slide 16
Why• Over 200 years experience in Forming fabrics• #1 Supplier of forming fabrics in Tissue-TAD in North
America• Now avai lable in EUROPE!
• Unique product line• Exclusive yarn technology• TAD fabric development expertise • Energy Efficient TAD Fabrics with ArmorTec™ T• Improved Stickies Cleaning with ArmorTec™ F
?