New Fabric Technology - TAPPI · 2010-05-27 · Press Tri-Np Btm Grade Uncoated Free •Fabrics run smooth early in life. Vibration increases after two weeks as the fabric compacts

TTL FRS 2010 | 2010-03-28 | 1

TAPPI

New Fabric Technology

Tom E. CoulterVP Product ManagementVoith Paper Fabric & Roll Systems

TTL FRS 2010, 2010-03-28

Agenda

� New Technology Development

� Next Generation Triple Layer Forming Fabric

� Next Generation Hybrid Technology Press Fabric

Papermaking Challenges Drive R&D Efforts

Health & Safety Energy Sheet Quality Production Environment

Global Product Development and Applied Research

Product Development Groups

Forming Press Drying

Research Technology Platforms

Material

Surface

Simulation

Textile/NW

Analytic

Fabrics & Rolls

Technology Scale up and Transfer

FIN

New technology tested at our Paper Technology Center

Next Generation Triple LayerDesigned to meet the full range of customer demands

A unique balance

Sheet Quality

� Industry high Fiber Support� Fines Retention� Formation� Cleaner runnability

� Industry high Open Area� headbox flows / formation

Performance

� Industry high Wear Volume� Life Potential

� Thin Caliper (down to 0.026”)� Couch Solids� Cleaner runnability

IS

Comparison of Features – Next Generation vs Conventional Triple Layer

0

50

100

150

200

250

0 75 100 125 150 175 200 225 250

ARI (Wear Volume value)

FS

I

Medium Mesh TL0.13 / 0.21mm

warpsets

Fine Mesh TL0.11 / 0.18mm warpsetsNext Generation

Next Generation - Results

Machine Data Results / Benefits• Exceptional fabric stability

• “most stable design we have ever run on Backing Position”

• Increased Drainage• Sheet Formation improved with higher headbox flows

• Industry high Wear Volume• Competition triple layer averaged 42 days• Next Generation has run 87 days

• Ran cleaner than other designs

330” (8.50 m)Width

4100 fpm (1250 m/min)Speed

BelBaie Former

Pulp Furnish

Woodfree-CoatedGrade

Run

ning

Tim

e [g

ays]

Next Generation TL

Standard TL

Mill Cost Benefits by Increased Backing Position Fa bric Life

BelBaie – WoodFree Coated

0

100.000

200.000

300.000

400.000

500.000

600.000

700.000

800.000

900.000

Fabric PurchaseCosts

Downtime Costs toChange Fabric

Total Cost ofOpperation

StanardNext Generation

Annual Costs of Operating

Backing Fabrics on PM7 Backing

� Fabric cost savings = $ 250,000

� Down time savings = $ 120,000

� Total Annual Savings = $ 370,000

Val

ue[U

S $

]


Machine Data Results / Benefits

290” (7.30m) Width3805 fpm (1160 m/min)SpeedDuoFormer DFormerNewsprintGrade •Significant increase in fabric wear potential

• TL competition averaging under 50 days• Next Generation has run over 100 days

• Increased mechanical retention• reduced Retention Aide usage / improved Formation• Reduced drive loads

• Improved MD stablity – limited Stretch Roll capacity

Run

ning

Tim

e [g

ays]

Next Generation

Standard


Lower power consumptionAdditional benefits

Cost comparison Competitor Voith

Fabric cost ($) $80 000 $84 000

Life time (days) 40 80

Fabric changes / year 9 5

Cost savings 300 000

Fabric costs ($/year) $720 000 $420 000

Additional benefits Reduced retention aid usage

DuoFormer D – Newsprint

Mill Cost Benefits by Increased Base Position Fabri c Life



330” (8.40 m) Width4100 fpm (1250 m/min)SpeedFourdrinierFormerLWCGrade

•Increased headbox flows compared to competition products

• cleaner HB operation / reduced wet end breaks• Improved Formation

• Eliminated Stock-On Stock-Off guiding issues• Improved Trim quality• Improved sheet 2-sigma profile• Excellent wear potential / excellent stability• Improved Couch Solids by 0.5 – 1.0%


Formation ImprovementAmbertec Formation (Standard Deviation – lower valu es = better formation)

Fourdrinier – LWC

0,59

0,57 0,57

0,54

0,59

0,62

Front Side Middle Drive Side

For

mat

ion

norm

aliz

ed (

√√ √√g/

m)

With PF ISW 2008-04-24 60g/m²

With competition 2008-06-26 60g/m²

0,640

0,630 0,600

0,600

0,660

0,670

For

mat

ion

norm

aliz

ed (

√√ √√g/

m)

For

mat

ion

norm

aliz

ed (

√√ √√g/

m)

-04- ²-04-

-06- ²- -Competition TLNext Generation TL


IS

Next Generation Series of Products

0

50

100

150

200

250

0 50 100 150 200 250 300 350 400

ARI (Wear Volume Value)

FS

I

Next Generation

GraphicsNext Generation

Graphics / B&PNext Generation

B&P

Press Fabric Innovation – Hybrid Technology

�Non-woven, elastomeric roll side structure.

� Elastomeric Yarn provides resiliency for vibration dampening and steady state pressing throughout felt life.

� Compressibility provides a quick startup and increased nip dewatering if applicable.

� MD rollside Flow Channels provide low MD flow resistance and increased dewatering rates.

Water Load to Reach SaturationFelt Inlet MR=0.25

Late Life

-400

-200

0

200

400

600

125 175 225 275 375

Press Load (pli)

Wat

er lo

ad (g

sm)

Triple Layer 1

Triple Layer 2

3 Layer HT

Water Load to Reach SaturationFelt Inlet MR=0.25

Early Life

-400

-200

0

200

400

600

125 175 225 275 375

Press Load (pli)

Wat

er lo

ad (g

sm)

Triple Layer 1

Triple Layer 2

Triple Layer HT

Resiliency Void Volume Differential between High and Low Loadi ngs

1.6

1.8

2.0

2.2

2.4

2.6

Triple Layer 1 Triple Layer HT Triple Layer 2

Voi

d V

olum

e (c

m3 /ft

2 )

15000 Cycles

115000 Cycles

380000 Cycles

Early Life

Late Life

Rate of Caliper Loss@ 225 pli

10

16

22

28

34

40

Triple Layer 1 Triple Layer HT Triple Layer 2

.001

" / m

illion

cyc

les

Press Fabric Innovation – Hybrid Technology


220” (5.6m) Width1000 fpm (300 m/min)SpeedOpen Draw 2ndPressCoated Bleached BoardGrade •Basis weight reduction on 8-12 pt. grades

•1.35% weight reduction, equates to 154 tons/month

•Customer verified $526,300 savings per year

G

W

G

W

HB HB

Basis Weight

Savings

Hybrid Technology Seamed Press Fabric Results


278” (7m) Width3000 fpm (909 m/min)SpeedTri-Np BtmPressUncoated FreeGrade •Fabrics run smooth early in life.

Vibration increases after two weeks as the fabric compacts and fills.

•HT fabric ran 32 days – scheduled off with no increase in vibration noted through run


HB HBHBHB

HBHB

G

PM63 - 1ST PRESS TEND SIDE1ST PR.TD -P3A #2 ROLL 1ST PRESS-PRESS ROLL AX

Route Spectrum 10-Nov-08 11:54:40

OVERALL= .0861 V-DG PK = .0858 AMPS. = 100.0 FPM = 2587. (6.11 Hz)

0 50 100 150 200 250 300 350 400

0

0.02

0.04

0.06

0.08

0.10

Frequency in Hz

PK

Vel

ocity

in In

/Sec

>SKF 23152CA FTF: 2.67 BSF: 23.36 BPFO: 53.32 BPFI: 68.79 >SKF 23152C FTF: 2.67 BSF: 23.64 BPFO: 56.13 BPFI: 72.09 >TOR 23152 FTF: 2.68 BSF: 24.27 BPFO: 56.30 BPFI: 71.92 >FAG 23152 FTF: 2.69 BSF: 24.73

PM63 - 1ST PRESS TEND SIDE1ST PR.TD -P3A #2 ROLL 1ST PRESS-PRESS ROLL AX

0 50 100 150 200 250 300 350 400

0

0.02

0.04

0.06

0.08

0.10

Frequency in Hz

PK

Vel

ocity

in In

/Sec


278” (7m) Width3000 fpm (909 m/min)SpeedTri-Np BtmPressUncoated FreeGrade •Fabrics run smooth early in life.

Vibration increases after two weeks as the fabric compacts and fills.

•Improved CD moisture profile variation by 40%


HB HBHBHB

HBHB

G


234” (5.9m) Width1300 fpm (394 m/min)SpeedDBL Felted 1st & 2ndPressCoated LinerGrade

•Increased press exit solids 1.5- 2%

•5.2% TPH increase on average

•Improved speeds all grades

•Lower uhle box vacuums over life

•3% reduction in basis weight on average


No. 6 Press Solids vs. Press Fabric Style

40.00% 42.00% 44.00% 46.00% 48.00% 50.00% 52.00% 54.00%

Avg

93 lb

105 lb

Bas

is W

t.

% Press Solids

VOITH HT 1st Press Other 1st Press VOITH HT 2nd Press Others 2nd Press

� Optimum “bridging effect“

� Lower flow resistance in Z-direction

� No groove closure

� Elimination of fabric wear (roll side)

� High uhle or nip dewatering depending upon application

� Optimum utilization of the void capacity under pressure

Combination of Poly Roll with maximum surface desig n with HT Fabrics will optimize press performance

Confid

entia

l

Optimum surface design:

Improving Dry-end Operation OEE (Overall Equipment Efficiency)

Introduction

• 27Years of experience in the P&P industry.

• 70+JumboMaster® systems installed.

• 1.2% average slab-off reduction.

• Different grades (Newsprint, CFS, LWC, MFC, SCA, Fine, Directory).

2

Introduction

• Installed on most machine builders equipment and vintages.

• In-depth analysis of data obtained from our systems demonstrated possible improvements:

- 0.35% losses on average.

- 10% productivity.

- $100,000 transportation costs.

3

Introduction

4

System Overview

Automated spool tracking

5

Reel technical interface

6

Winder technical interface

7

Varying Compression at the Winder

8

Closed Loop

Total Tear Off:SP: Total Bottom OrderedSP: Bottom OrderedSP: Bottom Bad PaperSP: Bottom AllocationSP: Top OrderedSP: Middle Bad Paper

Reel Break#Items / Jumbo

JumboMasterController

X

D

Compression Factor Algorithm(patented)

Reel turnup control loop

Drive

Controller

Winder stop control loop

Setpoint

D

DD

Speed

9

Reduced Variability - Foodboard sample

10

Optimization

Automation

Database

Reporting

Optimization

11

Benchmarking

12

Losses

13

Winder Productivity

14

Conclusion

Product type: Coated board.Production capacity: 300,000 tons/year.Expected efficiency increase: 1.0%

Total savings slab losses300,000 tons/year x 1.0%

3,000 tons/year of additional good paper.

15

Conclusion

Weight increase per roll: 1.0%.

Transportation costs1% per year in costs reduction.

Core and wrapping cost1% per year in costs reduction.

16

Improving Dry-end Operation OEE (Overall Equipment Efficiency)

Introduction

• 27Years of experience in the P&P industry.

• 70+JumboMaster® systems installed.

• 1.2% average slab-off reduction.

• Different grades (Newsprint, CFS, LWC, MFC, SCA, Fine, Directory).

2

Introduction

• Installed on most machine builders equipment and vintages.

• In-depth analysis of data obtained from our systems demonstrated possible improvements:

- 0.35% losses on average.

- 10% productivity.

- $100,000 transportation costs.

3

Introduction

4

System Overview

Automated spool tracking

5

Reel technical interface

6

Winder technical interface

7

Varying Compression at the Winder

8

Closed Loop

Total Tear Off:SP: Total Bottom OrderedSP: Bottom OrderedSP: Bottom Bad PaperSP: Bottom AllocationSP: Top OrderedSP: Middle Bad Paper

Reel Break#Items / Jumbo

JumboMasterController

X

D

Compression Factor Algorithm(patented)

Reel turnup control loop

Drive

Controller

Winder stop control loop

Setpoint

D

DD

Speed

9

Reduced Variability - Foodboard sample

10

Optimization

Automation

Database

Reporting

Optimization

11

Benchmarking

12

Losses

13

Winder Productivity

14

Conclusion

Product type: Coated board.Production capacity: 300,000 tons/year.Expected efficiency increase: 1.0%

Total savings slab losses300,000 tons/year x 1.0%

3,000 tons/year of additional good paper.

15

Conclusion

Weight increase per roll: 1.0%.

Transportation costs1% per year in costs reduction.

Core and wrapping cost1% per year in costs reduction.

16

MultiJet&Brush on-line cleaning system

• 350 installations worldwide

• Global industry leader for high-pressure water cleaning equipment

• Strong references with systems supplied to Europe, Asia and increasingly to North America

• Headquarters and production facility located in Huskvarna, Sweden

• Exclusive partnership with Andritz in NA

Business Overview

OfficesAgents / DistributorsReferences

Current Network

Network and References

For cleaning paper machine clothing, transfer belts and press rolls

For online and offline backing rolls

Introduction to the m-clean systems

Dryer Fabric cleaning Backing Roll cleaning Transfer belts & Press Roll cleaning

MultiJet&Brush will eliminate or minimize backing roll waste caused by:

• Coating streaks

• Coating colour residue

• Bleed through

• Shadow marks

• Butterflies

• Glue & Adhesive tape

• Fibres & Chemicals

MultiJet&Brush online cleaning system

MultiJet&Brush installed on backing rollMultiJet&Brush cleaning head

• Ø150mm brush for long service life

• Three different types of brushes

• Cleans all type of contamination without damaging the backing rolls

• Suitable for all type of roll covers

MultiJet&Brush - Brush specifications

• Change the brush in less than two minutes

• Brush can be changed during paper production

• Brush fitted with only one screw

• Cover easily removed and equipped with handle

MultiJet&Brush – Easy brush maintenance

• Efficient cleaning with high pressure water in combination with rotating brush and vacuum

• No negative effect in paper nor paper breaks during cleaning

• No moisture left on the backing roll

• Efficient cleaning of all types of surface contaminations

Benefits MultiJet&Brush concept

• Fast payback time of investment by:

• Minimizing backing roll related waste

• Minimizing still stand for backing roll cleaning at web break

• Decreased paper machine shut down time for manual cleaning

• Improved paper machine runnability

• Improved paper quality

• Guaranteed uptime

• Minimizing amount of web breaks

• Low maintenance cost

Benefits MultiJet&Brush concept

High pressure water

Vacuum and air

Siemens S7 or Allen Bradley

Control by Siemens S7 or Allen Bradley

MultiJet&Brush cleaning unit

One central unit can support several cleaning units

• Reduction of backing roll related paper breaks: up to 100%

• Improved machine up time: up to 5%

• No need for manual cleaning Saving/Safety

• No downgraded paper due to markings on the sheet Saving

• Elimination of rejected paper (printing house etc.) Saving

• Improved CD profile

Return on Investment

Documents

New Fabric Technology - TAPPI · 2010-05-27 · Press Tri-Np Btm Grade Uncoated Free •Fabrics run smooth early in life. Vibration increases after two weeks as the fabric compacts