2019 TAPPI

PAPER MACHINE
OPERATIONS COURSE

1
 TAPPI

Forming Fabric
Manufacture & Design
Kevin Kroon
Product Manager Forming - Publication Grades
May 2019

2
 Learning Outcomes
• Performance Functions of Forming Fabrics
• Forming Fabric Manufacturing
• Design Tools
• Properties of Forming Fabrics

3
 Paper Manufacturing
Cost of water removed
80%
70%
Fiber and Filler content 60%

% of Total Cost
50%
40%
1%25% 50% 95% 30%
20%
5,947 gpm 124 gpm 72 gpm 10%
0%
Forming Section Press Section Drying Section

+0.5% Forming = +1.0% Press = +4.0% Dryers = $ 4

 Paper Machine Clothing

90 days 45 days 360 days 270 days

 The Cost of Making Paper
Salaried
Power 9%
Total Cash Cost per Ton 9%
Clothing Chemicals
2% 24%

Materials
7%

Hourly
Labor
10%

Grade – Coated Freesheet

Total Cash Cost - $690 US Fuel
11% Fiber
34%

Paper Machine Clothing averages 2% of operating costs of a publication grade

machine, but has a significant impact on Energy, Fiber, and Chemicals
* Source: Fisher Pulp and Paper Worldwide 2007 (Fisher International Inc.)
 Paper Types
Pulp Grades
• Growth rate in China and rebound of NA and European markets drive NA pulp producers
• Moody Investors reports stable NA market with single digit growth
• Globally, pulp has never been below other sectors like metals, agricultural, oil and energy
despite some depression in 2009
• With growth of machines in China, and not much wood supply, the Chinese have continued
to import pulp from other areas of the world
Chinese Imported Pulp
 Paper Types
Kraft & Packaging Grades (Brown Paper)
• Generally follows consumer purchasing trends; good economy translates to high usage
and vice-versa
• Linerboard
• Corrugating Medium
• Kraft Bag
• Retail displays
• Cartonboards (milk carton & food containers)
• Cosmetics
• Cereal boxes
• Food containers
• Paper plates and cups
 Paper Types
Publication Grades
• Demand continues to decline w/ the switch to digital media
• Uncoated grades - Copy paper, Envelope, Book , Directory, Direct mail, Newsprint
• Coated grades – Annual reports, Magazine, Catalog, Advertising, Direct mail, Brochures
• Specialty – Label, Wrapping paper, Food Wrap, Popcorn bag, Oil-Resistant, Colored
papers
 Paper Types
Tissue Grades
• Steady demand and general trend towards softer and more absorbent tissue (esp. USA)
• TAD (Through Air Dryer) technology is spreading rapidly due to fiber savings and energy
savings
• Napkins
• Towel – white or brown
• Tissue – Facial / Bath
Fiber Preparation

Forming Fabrics
11
Early Flat Weaving

Shed

Warp
Shute

Seaming

12
 Manufacturing steps
Warping

Weaving

Inspection

Heatsetting

Sizing

Seaming

Finishing
Manufacturing Video
Inspection

Packaging

13
Heat setting – Crimp Transfer
WARP(MD YARN)
Woven Cloth

Heatset Cloth

TOP SHUTE(CD YARN)

Woven Cloth

Heatset Cloth

BOTTOM SHUTE(CD YARN)

Woven Cloth

Heatset Cloth

14
Forming Fabric
Design

15
 Mesh x Count

MD

CD
Mesh = Number of Strands / Inch in the Machine Direction
Count = Number of Strands / Inch in the Cross Direction

16
 Material and Filament Diameter
Warps = MD
• Mainly Polyester (PET)
• 0.08mm – 1.2mm

Shutes = CD
• From 100% Polyester to 100% Polyamide
• Blended materials
• Diameter paper side: 0.08 – 1.2mm
• Diameter wear side: 0.15 – 1.2mm

0.50mm

0.10mm
17
 Material Conditions

• Polyester (PET)
• Low elongation
• Low water absorption
→ High dimensional stability PET-filament fibrillation due to
intensive
high pressure shower cleaning
but
• Low abrasion resistance
• Low pressure resistance
→ Risk for fibrillation

PET-filament fibrillation due to

compression due to lump breaker
18
 Material Conditions

• Polyamide (PA) - Nylon

• High elongation
• High water absorption (3%-8%)
→ Low dimension stability
• High abrasion resistance
• Lower contamination with dirt
→ Long lifetime
• Higher friction values Acid destroyed PA filaments

→ Increased power consumption

• Not resistant against acid

19
Material Influence on Rate of Wear

20
Weave Pattern

5 Shed
Single Layer

7/14 Shed
TSS

21
 Forming Fabric Performance
Functions
Dewatering
Separation of fibers and water

Fabric
design

Transportation and power

Sheet formation and consolidation transmission
Optical and mechanical sheet properties Stability, running behavior, lifetime

Forming Fabrics
22
Maximized Drainage

20 x 20
0.12 x 0.12

23
Maximized Support
150 x 150
0.12 x 0.12

24
Maximized Transport

20 x 20
0.75 x 0.75

25
 Which design parameter do we have
available to create the necessary
compromise?
Material for CD and MD yarns Style and weave pattern

Fabric
design

Yarn diameter and number

Effects Fiber Support, Caliper, Void Volume,
Permeability, Life Potential

Forming Fabrics
26
 Fabric Properties
Air Permeability
Open Area
Frame size
Support Points / in2
Plane Difference
Void Volume & Distribution
Running Attitude
Wear Volume
27
Air Permeability

Air Flow:
CFM/ft2 @ 1/2” H2O

28
 Air Permeability
Air Perm. vs. Fabric Drainage

65
60
Drainage

55
50
45
40
300 400 500 600 700 800
Air Permeability (CFM)

Single Layer Double Layer

Double Layer SS Triple Layer

29
 Open Area and Frame Size

Forming Side OA & Frame Size Depends on

• Mesh and Count
• Weave Pattern
• Size of Yarns

30
 Forming Fabric Fiber Support
• Things that Affect Fiber Support
• Style & Weave pattern
• Surface topography
• Top MD x CD strand size

• To get a High Fiber Support Fabric

• Multi-layer fabrics
• Fine sheet side (plain weave)
• Long top Side CD knuckles
• High number of top CD strands

31
 Void Volume

Void volume is all of the volume not taken up

by the yarns

Void Volume Depends on:

• Mesh and Count
• Caliper of the fabric
• Size of yarns
• Weave pattern (single, double, triple)
• Materials

32
 Plane Difference

Monoplane
}
{

The difference in MD & CD strand height

Cross Direction

33
 Running Attitude

MD Knuckle Dominant CD Knuckle Dominant

34
Wear Volume – Life Potential

Wear Volume Depends on:

• Yarn Size
• Plane Difference
• Float Length
35
 Weave Patterns

Single Layer
(1 MD system 1 CD system)

Double Layer
(1 MD system 2 CD systems)

Triple Layer
(2 MD system 2-3 CD systems)

36
Single Layer Weave Patterns

5 Shed (2 x 3)

5 Shed (1 x 4)

5 Shed (1 x 4)
w/ support

37
 Forming Surface

Standard 5-shed 5-shed Single Layer

Single Layer w/ Support Strand
Sometimes referred to as 1.5 Layer

38
 Forming Basic Applications
• Pulp Fabrics & Kraft Forming Fabrics
• Coarse structure with high open area
• Pulp has high basis weight and slow draining furnish – Need lots of drainage
• Kraft has high recycle content – Needs lots of drainage, very open fabric
• Lots of drainage & vacuum elements – Need large WS yarns

• Tissue Forming Fabrics

• Very fast machines – Need very open fabrics
• Tissue machines do not typically have drainage elements – small WS yarns
• CD dominate sheet surface for fiber orientation – strength in both directions

• Publication Forming Fabrics

• Very high fiber support for good formation, retention, and printability
• Many different machine types – different drainage characteristics
• Many different machine types – medium WS yarns
 Application of Single Layers
Forming Side Forming Side Forming Side

Wear Side Wear Side Wear Side

40
Double Layer Weave Patterns

7 Shed

7 Shed w/support

8 Shed

8 Shed w/support

41
 Forming Surface

Double Layer Double Layer

w/ support
Sometimes referred to as 2.5 Layer

42
 Forming Surface
What do you see?

7-Shed Double 8-Shed Double

layer w/ support layer w/ support

43
 Open Area
(7 –Shed Double Layer Fabric at a 30 Degree Angle)

44
 Forming Basic Applications
• Pulp Fabrics & Kraft Forming Fabrics
• Coarse structure with high open area
• Pulp has high basis weight and slow draining furnish – Need lots of drainage
• Kraft has high recycle content – Needs lots of drainage, very open fabric
• Lots of drainage & vacuum elements – Need large WS yarns

• Tissue Forming Fabrics

• Very fast machines – Need very open fabrics
• Tissue machines do not typically have drainage elements – small WS yarns
• CD dominate sheet surface for fiber orientation – strength in both directions

• Publication Forming Fabrics

• Very high fiber support for good formation, retention, and printability
• Many different machine types – different drainage characteristics
• Many different machine types – medium WS yarns

45
 Application of Double Layers

Forming Side Forming Side Forming Side Forming Side

1 2 3 4

Wear Side Wear Side Wear Side Wear Side

46
Triple Layer Binding Technologies
Conventional CD Binder

Paired CD Binder (SSB) Fine or UltraFine

INLINE Binder

47
Triple Layer Weave Patterns
Forming Surface

48
Triple Layer Weave Patterns
Wear Surface

49
 Advantages of Triple-layer designs
• Higher Fiber Support • Better formation and retention of
fines and fillers
• Reduction in retention aid chemicals

• “A” Drainage Characteristics • Cleaner return run – less breaks

• Easier to clean

• Thin Caliper • High vacuum efficiency - Thin triple-

layers are similar caliper to older
double-layers giving similar couch
solids

• Drainage • Triple-layers tend to drain faster at the

same perm

Forming Fabrics
50
 MD Different SSB - CD ratios
1:1
1:1 CD Ratio

3:2
3:2 CD Ratio

2:1
2:1 CD Ratio

3:1
3:1 CD Ratio
Forming Fabrics
51
 Forming Basic Applications
• Kraft Forming Fabrics
• Coarse structure with high open area
• Pulp typically does not need triple-layer fiber support
• Kraft has high recycle content – Needs lots of drainage, very open fabric
• Lots of drainage & vacuum elements – Need large WS yarns

• Tissue Forming Fabrics

• Very fast machines – Need very open fabrics
• Tissue machines do not typically have drainage elements – small WS yarns
• CD dominate sheet surface for fiber orientation – strength in both directions

• Publication Forming Fabrics

• Very high fiber support for good formation, retention, and printability
• Many different machine types – different drainage characteristics
• Many different machine types – medium WS yarns

52
 Application of Triple Layers
Forming Side Forming Side Forming Side

Wear Side Wear Side Wear Side

53
Trim Bead – Tissue Application

• Trim bead used to trim sheet.

• Used mostly on Crescent Former
PM’s to carry trim to the Yankee.
• In some cases Trim Beads are
used to trim one edge, usually the
back edge, eliminating the trim
squirt.

54
Trim Bead – Tissue Application

Trim

Sheet Edge Crepe Blade

55
Paper Machine
Applications

56
 Stock Preparation / Fiber prep

• Stock prep uniformity = product uniformity

• Consistency
• Flows
• Degree and type of refining
• Furnish makeup including additives
• Broke
• Whitewater

57
So Where is the Value in the Forming Section?
Productivity (OEE)
• Higher efficiency / Reduced down time / Reduced breaks
• Faster start up
• Increased speeds

Raw materials
• Lower basis weight / Furnish mix TMP – DIP – HW & SW Kraft
• Filler addition for opacity, porosity and fiber replacement
• Better retention / reduction in retention aid
• Less coating - more even application

Energy consumption
• Lower drive loads / Reduced vacuum levels
• Less steam usage - better solids / drainage / water removal
• Refining energy to achieve strength tests

Forming Fabrics
58
 Better Uniformity and Profiles
Steam consumption
ton/ton paper 1,30
1,28

1,26

1,24

1,22

1,20

1,18

1,16

1,14

1,12

1,10

3,9 4,0 4,1 4,2 4,3 4,4 4,5 4,6 4,7 4,8

Beta Formation
Good formation gives lower steam consumption
• Higher dryness into the dryer section
• Floccy paper needs more energy to get an even
moisture profile
Forming Fabrics
59
 Better Uniformity and Profiles
Steam consumption
ton/ton paper

1,25E+00
)
g

1,20E+00
g

1,15E+00
(

1,10E+00

1,05E+00
2,8 2,9 3,0 3,1 3,2
Roughness, PPS

Smoother surface corresponds to lower steam consumption

• Rough paper has a lower heat transfer in the dryers

Forming Fabrics
60
 Types of formers

• Fourdriniers e
d
gA
eG

H
G

• Hybrid (twin wire)

• Gap formers 1
2

Forming Fabrics
61
Application Design Considerations
• Former Type
• Grades / Basis Weight / Speeds
• Drainage / Vacuum capacity
• Couch Solids
• Retention
• Cleanliness
• Power Loads
• Fabric Life
• PM History

62
 Fabric packaging & installation
Fabric installation
• Clean up, un-packaging and machine prep
• Good wash-up procedures, rolls in change position, wash
up/cover floor, cover framework, utilize quick disconnects
where possible
• Un-package per suppliers’ recommendations, proper
orientation before roll out

• No Knives to open package

Forming Fabrics
63
 Fabric packaging & installation

Fabric installation – (continued)

• Minimize MD creases, CD creases will pull out with tension

• No walking on ceramic covers

• Center & straighten fabric on machine before moving rolls

• Communication very important – crew meetings

• Document tradeline position at installation

Forming Fabrics
64
 Seamed Forming Applications
(Non-cantilevered machines)

Seamed Forming Fabrics

• Exclusively in Fiber prep &
Pulp
• Stuffers added to reduce
“open-ness” of seam

Forming Fabrics
65
 Seamed Forming Applications
(Non-cantilevered machines)

• Mesh loops together

avoiding any double loops

• Insert stainless steel attached

to pintle though spiral.

• Keep from bending pintle

leader

• Once stainless steel leader

exits the other side of seam
pull pintle straight out to
avoid damaging seam loops

Forming Fabrics
66
 General start up
Fabric start up
• Inspect the former and fabric to ensure installation tools,
packaging materials, etc. are removed.

• Full volume flooded nip showers & HP showers are not on

without fabric in run mode.

• Crawl the fabric. Tension fabric while the fabric is moving.

Guiding & tension monitored during crawl. Guiding mechanism
checked for proper direction hand guide versus auto-guide
• High vac box bleeds opened
• Lube showers on inlet side of ceramics turn on automatically
with stock off.
• Wash out the nips, jogFabrics
Forming , repeat, inspect
67
 General start up
Fabric relaxation and elongation
• Forming fabrics relax (shrink in length) over time when tension
is not applied. 24 – 48 hours to remove the under normal start-
up conditions.
• Applied stock and vacuum will accelerate this process, critical
to monitor & maintain fabric tension
• During fabric shutdown & maintenance, the fabric should be
kept at low tension.
• Forming fabrics should not be completely slacked-off, if
possible.
• This will allow the fabric to maintain flatness and straightness
properties.

Forming Fabrics
68
 Some problems in the forming section
• Furnish • Couch (seals, deckles,
• Stock approach (fan pump, cleaners) condition)
• Chemistry (additives) • Drives
• Fillers • Trim squirt cut
• Temperature • Pick-up or open draw
• Headbox (delivery, movement) • Ribbon handling
• Deckle boards • Showering (lube, HPS,
edge)
• Edges
• Guiding
• Forming board (open area, tilt)
• Roll condition
• Gravity foils (height, angle, amount, type)
• Roll Speed
• Table Activity
• Tension (stretch)
• Drainage (adequate, elements, split)
• Alignment
• Vacuum limitations
• Forming Fabric
• Water handling
• Anything not listed

Look & Listen –Forming

WhyFabrics
is something different?
69
 Forming Section Audit Tools
• Furnish • Cleanliness – break reduction
• Fiber analysis - types • Fabric conditioning - fabric life
• Consistency
• Refining – Freeness study • IR Study – profiles
• Approach flow pulsation • Returned fabric analysis
• Headbox & jet delivery • Vibration analysis
• Activity table survey • Drive load study – power
• Fiber Orientation (TSI/TSO) • Preventing damage
• Drainage survey
• Vacuum audits
• Fabric Tension
• Trim Squirt Operation –
edge break reduction

Forming Fabrics
70
 CUSUM – Data Analysis
CUSUM – Cumulative Sum – Change in process detection

• Extremely powerful tool to

determine shifts in data along a
time line

• Used with several different

variables can help to determine
a root cause

• Care has to be taken to

determine if specific variable
caused the shift or was a result
of the shift

Forming Fabrics
71
 Approach flow - Pulsation
• Measures pressure fluctuations in stock lines from rotational
elements – pumps and screens

• Pulsations can cause MD variation and barring

• Determines frequencies of variation though Fast Fourier

Transformation (FFT) of time pressure signals

• Examine variations for correspondence with barring

tendencies ~ 35 – 50 Hz

• Uses pressure transducer, accelerometer, and Spectrum

Analyzer

Forming Fabrics
72
 Approach flow – Pulsation Study
HC STOCK FLOW
INLET PULSATION
LINE PULSATION TAP DAMPENER

LC STOCK INLET
LINE PULSATION TAP

LC STOCK DILUTION
RECIRCULATION LINE TAP
HC HEADBOX TAPERED
HEADER
RECIRCULATION LINE TAP LC DILUTION
STOCK FLOW
SYSTEM

LC DILUTION SCREEN
SCREEN RPM'S – 607.37
MOTOR RPM'S – 1782

DILUTION FAN PUMP

1424 RPM'S

SECONDARY SCREEN PRIMARY SCREEN

UFWW SUPPLY PUMP SCREEN RPM'S – 258.20
Chest 893 RPM'S MOTOR RPM'S – 894
WIRE 6 X 6 FOIL BLADES
SILO

SECONDARY PRIMARY SCREEN

SCREEN RPM'S - 384
Forming Fabrics
MOTOR RPM'S - 1792
PRIMARY FAN PUMP
636.89 RPM'S 73
 Thin Stock Flow Recirculation Line from
Headbox Tapered Header
• 14 Hz is 1X, 29 Hz is 2X and 44 Hz is 3X rotational frequency of Secondary Cleaner Pump
• 23.7 Hz is 1X, 47.4 Hz is 2X rotational frequency of Consistency (Dilution) Pump
• 60.7 Hz is 6X rotational frequency Consistency (Dilution) Screen

PM1G - HEADBOX PRESSURES IN-OUT

HBX IN-OUT-O02 OUTLET HEADBOX PRESSURES 0-6000
0.5
DATA RECORDED RECIRCULATION LINE FROM HEADBOX TAPERED HEADER Analyze Spectrum
P-P Amplitude in PSI

0.4 25-Jan-16 10:37:26

OVERALL= .8598 G-DG
P-P = .8583
0.3
29.79

60.72
47.49
LOAD = 100.0
14.89

RPM = 384. (6.40 Hz)

23.77

0.2
44.69

0.1

0
0 20 40 60 80 100
Frequency in Hz
1.5
Analyze Waveform
1.0 25-Jan-16 10:37:26
Amplitude in PSI

P-P = .8798
0.5 PK(+/-) = 1.00/1.21
CRESTF= 3.89
0

-0.5

-1.0

-1.5
Freq: 14.89
0 10 20 30 40 50 60 70 Ordr: 2.327
Time in Seconds Spec: .146

Forming Fabrics
74
 Stock Activity
• Stock activity prevents re-flocculation (lumpiness)

• Activity continued until sheet is maximum 6-8%

consistency

• Stock Activity can be documented with high speed

digital cameras and strobe lights – (Schmid scale 1-10)

Forming Fabrics
75
 Activity Survey
• Observe table activity with
strobe light and high speed
camera
• Activity prevents reflocculation
and lumpiness

• Dependent on speed, angles of

gravity foil blades, furnish and cons.
• May correlate to formation – But
trial and error

Forming Fabrics
76
 20 Vacuum Audits
15

% solids
10

0
0 .01 .02 .03 .04 .05

Dwell (seconds)

• “Climb the curves”

• Stay on steepest parts of the curves
• Maximize water removal with “cheap” low vacuum
• Stay off flat part of curve (box becomes brake, not dewatering device)
• Always graduate vacuum

Forming Fabrics
77
 Vacuum Audit
• Observe vacuums, dewatering and calculate potential gains
• In this instance, everything looked pretty good
• Vacuum is graduated, vacuum curve looks good
• Every flatbox is taking water
• Predicted solids were 18.2% vs. 18.8% with microwave gauge
FB1 FB2 FB3 FB4 FB5 Couch HV Solids Drag
(in Hg) (in Hg) (in Hg) (in Hg) (in Hg) (in Hg) (%) (HP)
3.5 6.6 6.5 9.5 12.9 19.0 18.2 466
2.0 3.0 4.0 5.0 15.0 19.0 18.2 377
Corner Brook 7 Optimized
Corner Brook 7 As found This predicts the performance of high vacuum dewatering based on flat box config,
This predicts the performance of high vacuum dewatering based on flat box config, speed, wt., csf, %in, and vac:
20.0%
speed, wt., csf, %in, and vac: BOLD = inputs
20.0%
BOLD = inputs CD width: 287 in. 15.0%
CD width: 287 in. 15.0% frict coef SiN: .09
frict coef SiN: .09 coef Alumina: .12 10.0%
coef Alumina: .12 fric coef poly: .15
10.0%
fric coef poly: .15 wire speed: 3800fpm 5.0%
wire speed: 3800fpm basis weight: 9#/1000
5.0%
basis weight: 9#/1000 basis weight: 28#/3000 0.0%
basis weight: 28#/3000 0.0%
after transfer box
after transfer box ingoing solids: 5.6%in 9slots 6slots 9slots 6slots 33% 45% ope n 45% ope n
ingoing solids: 5.6%in 9slots 6slots 9slots 6slots 33% 45% ope n 45% ope n compositeCSF: 100 CSF 0.75in 0.75in 0.625in 0.75in 12.5in 6.50in 3.50in
compositeCSF: 100 CSF 0.75in 0.75in 0.625in 0.75in 12.5in 6.50in 3.50in freeness: 100 CSF 2.0inHg 3.0inHg 4.0inHg 5.0inHg 15.0inHg 12.5inH g 19.0inH g

freeness: 100 CSF 3.5inHg 6.6inHg 6.5inHg 9.5inHg 12.9inHg 12.5inH g 19.0inH g csf factor: box coef frict: 0.09 0.09 0.09 0.12 0.11 00
csf factor: box coef frict: 0.09 0.09 0.09 0.12 0.11 00 DWELL (sec): 0.009 0.00592105 0.0074 0.0059 0.0054 0.0038 0.0021
DWELL (sec): 0.009 0.00592105 0.0074 0.0059 0.0054 0.0038 0.0021 Box MD width (in.): 13.5in 9in 11.25in 9in 8.25in 5.85in 3.15in
Box MD width (in.): 13.5in 9in 11.25in 9in 8.25in 5.85in 3.15in %in: 5.6% 6.7% 7.8% 9.5% 11.2% 17.1% 17.5%
%in: 5.6% 7.4% 10.4% 13.1% 15.7% 17.4% 17.6% %out: 6.7% 7.8% 9.5% 11.2% 17.1% 17.5% 18.2%
%out: 7.4% 10.4% 13.1% 15.7% 17.4% 17.6% 18.2% gpm: 325 213 248 167 330 16 21
gpm: 480 400 213 135 66 9 19 req'd outlet pipe dia.: 9 7 8 6 9 2 3
req'd outlet pipe dia.: 10 10 7 6 4 2 2
Box Drag = 466 hp 348 kw, just flat boxes
Forming Fabrics Box Drag =
original:
377 hp
466 hp 89 hp
281 kw, just flat boxes
saved
78
 Drainage Survey
• Most forming fabric suppliers do drainage surveys with microwave
gauge
• Microwave gauge measures the amount of water weight
• Drainage surveys are meant to be a snap shot in time
• There is a lot of error in the measurements. It is not regarded as an
absolute determination of solids
• Very useful in trending on a certain grade, basis weight or speed
• Very useful in doing trials under same machine conditions

* Photo courtesy of Cristini FIBERSCAN

Forming Fabrics
79
 Drainage Survey
• Calculates sheet
consistency at each
measurement point
• Calculates dewatering %
of each element
• Calculates solids loss at
each element
• Like to see gradual solids
gain

Forming Fabrics
80
 Infared (IR) Thermography Audits

• IR Thermography is a relatively
new tool in the industry to show
temperature or moisture variation
• Very good at looking at profile
problems
• FLIR now has a camera that can
attach to a cell phone

* Photo courtesy of FLIR

Forming Fabrics
81
 Fabric Tension

Example: Tension trend on an Fourdrinier

10 kN/m

6 kN/m

The fabric tension is not constant over the complete fabric loop

82
 Principles of Guiding
LEAD-OUT ROLL
LEAD-IN ROLL GUIDE ROLL

Trade Line

First Contact

PADDLE

83
 Guiding Theory
Fabric will attempt to leave the guide
roll at a 900 angle to the roll.

Fabric will Fabric will

guide in this guide in this
direction direction

Guide Roll Guide Roll

Fabric Travel

84
 Guiding Theory
Under traction, fabric
will attempt to leave Drag elements push
the guide roll at a 900 opposite direction of a
angle to the roll. rotating roll (snowplow)

Fabric will Fabric will

guide in this guide in this
direction direction

Guide Roll Gravity foils

Fabric Travel

85
 The guide roll is not the only roll
which can “guide” the fabric.

o
Any roll with over 10 of wrap can move the fabric if it
is not square or level in the machine.

Forming Fabrics
86
 Contributing Factors to Guiding
• Fabric tension
Higher tension provides better grip on roll

• Roll hardness
Softer roll cover allows fabric to grab roll easier
Worn cover can slip and causing skating

• Installation
Knockdown fourdriniers, breast roll mounting.

• True fabric on installation

Fabric can have a memory if tension applied without
truing
87
 Contributing Factors to Guiding
• Reaction time of guide roll
Tune slower to prevent chasing
Air Lines check for leakage
Check slide (if app.) for corrosion and sticking

• Guide movement & travel

Guide must be free moving and have adequate travel
Mechanical stops have been found to be too restrictive

• Wrap on guide roll

Minimum recommended = 25o
Up to 40o may be necessary depending on position of
adjacent rolls 88
 Contributing Factors to Guiding
• Adjacent roll geometry
Distance between lead-out roll & lead-in roll should equal
fabric width

Distance between lead-in & guide rolls should equal 2/3 of

fabric width - Allows good maneuvering of fabric

Distance between guide & lead-out rolls should equal 1/3

of fabric width - Allows guide to hold correct of fabric travel

89
 Guide Adjustments
Make small changes!

• Load
Basis weight, speed, furnish, refining, etc..

• Vacuum
• Sheet break
Stock on, stock off situations

• Fabric tension
• Fabric change
Design

90
Other Fabric Guiding Mechanisms
• Return rolls
• Table rolls
• Table elements
• Top units
• Dandy rolls
• Lump breakers
• Couch roll
• Pick-up roll
91
 Forming Fabric Cleaning Strategy
• Create constant fluid motion to the sheet side
• Then utilize outside rolls with doctors and showers to flush wire.
• Inside rolls & catch pans for stapled fibers.

92
 Forming Fabric Cleaning Strategy

Get contaminants OUT of fabric

 Flooded nip
 Wash roll
 Inside high pressure shower

Get contaminants OFF fabric

 Outside high pressure shower
 Wash roll
 (flooded nip)

93
 Flooded Nip Roll Shower

• Essentially a positive displacement device

• Only when Running Void Volume (or greater) is achieved
• Is dependent on:
• PM speed
• Wire’s flow resistance
• Wire and roll slip
• Angle of spray

• Hydrostatic intensity in nip

• Should be visible on drive load

• Consider the water source

• Filtration for clarified WW

94
 Flooded Nip Drive Roll Shower
Adjusting the spray angle

• Too high (most are)

• Does not develop the high

amplification force in the nip

• It becomes no more than a low

intensity flushing shower

• Direct to “bounce off the roll

• Overcomes roll slip – maximum super-
charging of the positive displacement
nip action

95
 Flooded Nip: What’s the Down Side?

• Volume
• A big, fast machine will require 1000+ gpm to achieve RVV
• That’s a lot of water!
• Can couch pit handle this volume continuously?

• Is the water available?

• Water Quality
• Few mills have 1000 gpm of fresh water
• These showers almost always use filtered white water
• If the shower is run continuously, whatever is left in that water is
relentlessly put into the wire
• Downstream buildup?

96
 Alternative: Sheet side wash roll

Shower placement and Configuration

• Install Inside High pressure fan shower (blue) directly on roll/wire
separation point angled with the run
• Roll wetting shower (yellow) provides the boundary layer that
develops the surface tension
 Vacuum of water leaving roll draws out contaminants

• Existing doctor’s mechanical application, surface tension & shower

pressure
 Very effective alternative to flooded nip
RR #1
RR

97
 High pressure water jet
As distance increases laminar flow turns turbulent
Energy

98
 High Pressure Showers
Maximize surface cleaning effectiveness, increase to > 6 in

shower
effectiveness

Maximize through cleaning effectiveness, < 4 in

99
 HPS Jet Angle
• “Chasing” wire for INSIDE
Shower Resultant vector
stream
(from contaminant frame of
reference) into fabric depending
on speed match

Fabric “through cleaning”

speed

• “Chiseling” wire for OUTSIDE

Shower
stream
Resultant vectors apply energy to
surface contaminants, and use some
energy to get contaminants OFF
fabric
Fabric
speed “surface cleaning”

100
 High Pressure Shower Placement
• Inside
• 4 inches (or less) from fabric
• Null jet vector following angle – (10o - 12o)
• Calculate angle
• Slight following angle
• Find angle with optimum through flow
• Pressure depends on fabric 350 psi good start

• Outside
• 6 inches (or more) from fabric
• Chiseling angle
• 15o is good place to start
• On roll for optimum energy transfer
• Optimize shower angle for reflected spray control
• Pressure depends on fabric – 350 psi good start

101
 HPS Jet Angle
• Example “Chiseling” wire for OUTSIDE HPS

102
 HPS Oscillation
Complete coverage is essential:
 Oscillator must stroke full integer multiple of the nozzle spacing
• Example; 6” nozzle spacing would require 12” oscillator stroke
• Insure stroke evaluation is noted at the shower (not oscillator)

 2X or even 3X stroke allow for poor performing nozzles

Example (left) shows a

“non-forgiving” single
stroke length situation
with one nozzle plugged
note 6” streak

Forming Fabrics
103
 HPS “END EFFECT”

Edges do not get the HPS

coverage the remaining width
of the fabric gets

Extra nozzle adds wet band at

each side due to additional
HPS on face side

Adding extra “outboard”nozzle

with shield provides even
coverage Sheild

Forming Fabrics
104
 Lubrication fan showers

What do you see?

Forming Fabrics
105
 Fan Showers
• Fan showers apply water evenly across the whole
CD width
• Pressure doesn’t matter
• Spray energy is immaterial
• Pressure is important only as far as it determines volume
distribution - Fan development

• Single coverage is inherently streaky

• Multiple coverage / overlap is much better
• Double is good
• Triple is great

106
 Worn Doctor Blades
Example: 45° bevel, load pressure 1.5 PLI, blade angle 25°

New blade, specific pressure Fully worn bevel, specific pressure

on 0.008” contact width is 5895 PSI on 0.117” contact width is 500 PSI

As blade wears, doctoring effectiveness goes down

A LOT!

107
Worn blade, too much pressure

• Doctor turns into contaminant compactor

• Poly is NOT the ideal doctor material

108
Doctor blades

Anything you see?

109
 Trim Squirts Positioning

Correct trim nozzle adjustment

means:

• Suitable MD angle
• Suitable CD angle
• Adequate water pressure
• Proper double jet alignment

110
 Trim Squirt Jet Shape

Left:
• Non laminar jet is called TURBULENT.
• It will break into individual droplets very
soon after leaving the nozzle.
• This affects the cut quality leading to
deterioration of showering efficiency
and uniformity.

Right:
• A laminar jet keeps its perfect shape
on greater length.
• The edges of the trim cut are uniform
and straight.

111
 Trim Squirts – What to avoid
Water Drops

1 2 3

• Water drops splashed by a roll, are falling on

the squirts area and crossing the jets.
• Depending on the size of these drops, edge
problems will happen.
• Sheet breaks
• Edge cracks
• Edge drop-off
• S/P picking (wet edges)

112
 Buildup On Trim Nozzles
Fiber buildup may be caused by:
• Poor nozzle quality
• Improper geometric adjustment
• Nozzle shape and dimensions
• Water temperature

#1 #2 #3

Picture #1 Picture #2 & #3

Dry deposit (nozzle fed with warm water) Wet buildup due cold water supply

113
 Buildup on Machine Frame

This buildup is caused due to:

• Water pressure might be too high

• The nozzles are worn out
• The second jet is splashing fibers
forward
• The distance to the wire is too small
• The angles are poorly adjusted
• The water temperature is low
• Air in the system

114
 Fabric Removal
• Wear
• Filling (pluggage)
• Drainage (too low or too high)
• Marking
• Instability (wrinkles, ridges, skew)
• Sheet breaks
Fabric skew
• Sheet release
• Moisture profile
• Basis weight profile
• Damage

Puncture damage to forming fabric 115

 Visual Wear Evaluation
The wear side ellipse has not yet
reached full strand width
~ 25% worn

The wear side ellipse has reached

full strand width
Running direction

~ 50% worn

In the middle of the ellipse there is

a diameter reduction
(hour-glassing)
~ 75% worn

CD Filaments broken in the middle,

MD filaments worn significantly
~ 100% worn

116
Returned Fabric Analysis

Forming Fabrics
117
 Increasing Life Potential (other tools)
• Minimize run time without stock on
Former up to run speed as little time as possible (<10-15 min) before putting
stock on or go to a crawl or intermediate speed
• Minimize potential damage sources (rust, debris, etc.) –
Anything that touches the fabric can be a source of excessive
wear
• Edge deckle heights • High vacuum edge deckles
• Lump breaker pressure • Roll Speeds
• Roll conditions • Foil conditions

Forming Fabrics
118
 Increasing Life Potential (other tools)
• Acid Boilout Precautions
Less than 2% concentration
Less than 140oF
Less than 4 hours dwell time
Polymer blends - other materials and blends are under constant
development
• Edge wear beads
Polymer beads added at a specific location and spacing near the
edges to prolong life.
Care must be taken not to get edge beads too close to the edges of
the stock or trim squirts.

Forming Fabrics
119
 Increasing Life Potential (other tools)
• Larger diameter strands
Larger diameter strands can change fabric permeability,
caliper, and sheet support characteristics.

• Triple layer design

Same triple layer design with larger wear side strands

• Forming Fabric Design Specifications

Different forming fabric designs, due to the weave
patterns, yarn sizes, and yarn count levels, have
inherently different fabric life potentials.

Forming Fabrics
120
Fabric Damage
Example
 Fabric Damage and Repair
Considerations for Repair

 Size of hole

 Number of holes

 Damage surrounding hole(s)

 Age of fabric(s)

 Downtime available for repair

 Fabric inventory levels

Types of Damage
Puncture
 Types of Damage
Ridging due to debris embedded in a roll

Found debris in WTR

Ridged 2 fabrics before
finding the debris
 Types of Damage
Examples of Mechanical Damage

Wear side scoring Abrasion – Excessive wear

 Types of Damage
Debris crushing fabric into apron
Types of Damage
White pipe dope
 Types of Damage
Examples of Mechanical Damage

HP Shower Damage Welding Slag

 Repair Method
Adhesive patch

Can be effective on smaller, slower, one fabric machines

Cleaning the forming fabric a must
High Pressure Shower pressures may have to be reduced
Doesn’t usually last
 Repair Method
Single Strand Method

MD
 Repair Examples

Woodfree uncoated
MD Slit – Repair ran to life
Repair Examples

Kraft grade

Ran 1 week - till next outage

Repair Examples

Woodfree specialty
(still ran 3mo. later)
 Other Types of Repairs
 Wrinkles
 Use conventional iron to smooth (water may help)
 Use care as too much heat damages
monofilament (< 325oF)

 Edge damage
 Heat seal raveled edges with Thunder Bolt iron
 Dope raveled edges with glue type material to
bond strands together
 Trim damaged areas & heat/dope seal edge
Thank-you

135