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

?