Creping

•Introduction
•Definition of Creping
•Types of Creping
•Types of Crepe
•Hardware Geometry
•Theoretical Model
•Process Variables
•Sheet Properties
•Coatings
 Creping

Crepe
Structure
Formed
Yankee Dryer

Reel Doctor Wet Press

Blade
 Uncreped
Sheet

Yankee Dryer

Creped
Sheet

Blade Holder
Creping Changes the Sheet
From

To
 Typical Dry-Crepe Machine

Felt Hood

Former Yankee
Dryer Reel

Creping Blade
 Creping

•Introduction
•Theoretical Model
- Macroscopic Model
- Microscopic Model
•Hardware Geometry
•Process Variables
•Sheet Properties
•Coatings
 Coating
Adhesive Uncreped
Sheet
Yankee Dryer

Creped
Sheet

Pocket
Angle

Blade
Extension Grind
Blade Angle
Wear
Angle
Blade Holder
 Mechanism of Creping
Yankee Microfold
YANKEE
YANKEE
Dryer Microfold (Primary Crepe)
DRYER
DRYER (Primary Crepe)

Macrofolds
Doctor Blade (Secondary Crepe)
Macrofold
(Secondary Crepe)
 Creping Analogy

90E
95 km/hr Pocket 6m
Angle

MG SHEET CREPING
BLADE
Failure Mechanisms in Compression
P
P P
Lateral Lateral
Supports Supports

Shear
Zone

P
P P
(a) Shear-slip-plane (b) Bending mode (c) Bulging mode
mode (brittle) (internal rupture)

We want this
kind of failure
Crepe Structure Measurement
Crepe
Wavelength

Folding Crepe
Radius Amplitude
Creped Sheet

100X Actual Size

 Creping

•Introduction
•Theoretical Model
•Hardware Geometry
•Angle Definition
•Inter-Relationships
•Measuring Blade Angles
•Process Variables
•Sheet Properties
•Coatings
Creping Geometry
Yankee Tangent Line

Yankee Tangent

Yankee
Dryer

Creping Blade
Creping Geometry
Blade Wear Angle

Yankee Tangent

Yankee
Dryer

Creping Blade
Blade Wear
Angle
Creping Geometry
Blade Grind Angle

Yankee Tangent

Yankee
Dryer

Blade
Grind
Angle
Creping
Blade
Creping Geometry
Creping Pocket Angle

Yankee Tangent

Yankee
Dryer
Creping
Pocket

Creping
Blade
Creping Geometry
Creping Angle Summary
POCKET = 90 - WEAR+ GRIND

Yankee Tangent

Yankee
Dryer

Blade
Grind
Angle
Creping
Blade
 Creping Geometry
Sheet Take-Off Angle
SHEET-TO-BLADE + TAKE-OFF = POCKET

Sheet
Take-Off
Yankee Angle
Dryer

Creped
Sheet

Creping
Yankee Blade
Tangent
Creping Geometry
Sheet to Blade Angle
SHEET-TO-BLADE + TAKE-OFF = POCKET

Yankee Creped
Dryer Sheet

Sheet-to-
Blade Angle

Yankee Creping
Tangent Blade
Effect of Creping Pocket Angle
Crepe Amplitude vs Creping Pocket Angle

0.6
Crepe Amplitudes, mm

Yankee Tangent
Yankee SECONDARY
0.5 Dryer CREPING
POCKET PRIMARY
0.4 Creping
Blade
0.3
0.2
0.1
0
65 70 75 80 85 90
Creping Pocket Angle, degrees
Reflective Wear Angle Gauge

Flashlight Angle Finder

Sighting Tube

Magnet Micarta Block

Doctor Blade

Base
Typical Dry Creping Geometry
O
Blade Wear Angle 12 - 24
O
Blade Grind Angle 0 - 15
O
Creping Pocket Angle 82 - 88
O
Sheet Take-Off Angle 52 - 68
O
Sheet-To-Blade Angle 12 - 30

Blade Extension 12 - 19 mm

Blade Thickness 0.65- 1.25 mm

Loading Pressure 2.6 kN/m (15 pli)

Creping Mechanism
Effect of Pocket Angle

Primary & Secondary Crepe

Pocket Angle < 80

Primary Crepe Only

Pocket Angle > 80

Creping Mechanism
TISSUE CROSS SECTIONS

Creping Pocket Angle =O 65

Creping Pocket Angle =O 80

 Creping

•Introduction
•Theoretical Model
•Hardware Geometry
•Process Variables
•Pocket Angle
•Adhesion
•Basis Weight
•Uncreped Sheet Properties
•Sheet Properties
•Coatings
Creping Mechanism
Effect of Adhesion Level

LOW ADHESION
Coarse, Skippy Crepe

HIGH ADHESION
Fine, Uniform Crepe
 Creping Mechanism
TISSUE CROSS SECTIONS

Dryer Adhesion = 2.3 gram per inch

Dryer Adhesion = 12.2 gram per inch

Effect of Adhesion on Crepe Amplitude

0.15

0.13

0.11

0.09

0.07

0.05
2 4 6 8 10 12 14 16
Sheet-To-Dryer Adhesion (g/in)
 Creping Mechanism
UNCREPED
#1 SECTIONS
o
Low Adhesion, Pocket < 80
PRIMARY &
#2 SECONDARY
CREPING
o
High Adhesion, Pocket < 80
PRIMARY
#3 CREPE
ONLY
o
High Adhesion, Pocket > 80
Effect of Basis Wt on Crepe Amplitude

0.11

0.09

0.07

0.05

0.03
8 10 12 14 16 18 20
Basis Weight (gsm)
 Creping

•Introduction
•Theoretical Model
•Hardware Geometry
•Process Variables
•Sheet Properties
•Creping Moisture
•Strength
•Debonding
•Crepe ratio
•Coatings
Sheet Debonding

200X
Debonding In Creping Process
Effect of Adhesion and Blade Geometry
100
80 o
80 Pocket
60
40 70o Pocket
20
o
0 60 Pocket
0 4 8 12 16 20
Adhesion To Dryer (g/in)
Dryer Adhesion vs Sheet Dryness

FT 94
TAPPI

50 60 70 80 90 100
Sheet Dryness, %
 Strength - Softness Curve
Facial Tissue
12
10
QAL Softness

6
4
2
0
0 200 400 600 800 1,000 1,200 1,400

Invariant Tensile Strength (g/ 3” sheet)

Strength - Softness Curve
Facial Panel Softness

12
10
8
6
4
2
0
0 400 800 1,200 1,600 2,000
Invariant Tensile Strength (g/3”)
 10

8
Softness

4
Historical Line

Closed Pocket Angle

2
Open Pocket Angle

Very Open Pocket

0
600 1,000 1,400 1,800 2,200
Overall Strength (g)
 Panel Stiffness
Facial Tissue Brand / Sheet Debonding
Structural Comparison vs. Stiffness
% Debonding/ Sensory Panel
Length Stiffness
Marcal 15.0 7.4

Secondary Fiber Kleenex 30.0 6.0

Virgin Fiber Kleenex 30.0 5.0

Regular Puffs 37.5 5.8

Kleenex Softique 45.0 4.5

New Puffs 55.0 3.6

 Crepe Ratio
Crepe Ratio = V2 / V1
where:

V2is Reel surface speed

V1 is Yankee Dryer surface speed

Reel Doctor
Blade
Bulk Development in Creped Wadding
0.8

0.6

O
0.4

80O Pocket
0.2
O
90 Pocket
0
1 2 3 4 5
Crepe Ratio
Debonding In Creping

Weak Points
KOTEX ® TYPE WADDING
Closed Pocket, High Adhesion

Uniformly Debonded, No Weak Points

KLEENEX ® FACIAL WADDING
Open Pocket, High Adhesion
 Creping

•Introduction
•Theoretical Model
•Hardware Geometry
•Process Variables
•Sheet Properties
•Coatings
•Definition
•Inorganic Coatings
•Organic Coatings
•Application Systems
 "Natural" Coatings "Advanced" Coatings
Title of Chart

Title of Chart

Organic From Organic From

Fibers Fibers
Inorganic
Salts
Inorganic
Salts Synthetic
Additives
Embedded
Embedded
Fibers
Fibers
 Inorganic Salts
Title of Chart

•100 ppm Calcium Organic From

needed to form good Fibers
coatings
Inorganic
•Some must harden Salts
water to achieve

•More than 600 ppm Embedded

will cause excessive Fibers
scaling elsewhere
 Creping Adhesive References
Poly-(aminoamides) Winslow.Spicer 1972:Giles.Espy 1975:Oliver
1980:Schoreer et al.1982: Soerens 1985.1987 :
Obokata.Takizawa 1990
Polyamides Lazorisak et al. 1977: Pomplu.Grube 1984 : Marzullo
1987: Chen et al. 1989: Soerens 1991
Polyamines Lazorisak et al. 1977: Latimer.Stevens 1983: Soerens
1991
Polyvinyl Alcohol Bates 1975: Grube.Ries 1981: Pomplun.Grube 1984:
Soerens 1985 : Pippen 1987; Soerens 1987: Chen et al.
1989:Soerens 1991
Polyvinyl acetate & Grossman1977: Lazorisak et al.1977: Grube.Ries
copolymers 1981: Pomplun.Grube1984 : Pippen1987: Chen et al
1989
Polyethers & copolymers Pomplu.Grube 1984: Soerens 1991 : Lazorisak et al.
polycrylic acid 1977:

Animal glue Fuxelius 1967: Sanford.Sisson 1967: Lazorisak et al.

1977: Oliver 1980
Starch Fuxelis 1967: Salvucci. Yannos 1974: Oliver 1980

Cellulose derivatives Grossman 1977: Marzullo 1987

Components of Adhesion
Title of Chart

Diffusion
Absorption

Mechanical
Interlocking
Electrostatic
Attractions
Weak
Boundary
Acid-Based Layers
Interactions
Chemical
Bonding
Strong adhesion between materials
is governed by two interactions:

• Intimate molecular contact closer than 9

angstroms (0.0000000009 meters). This is a
necessary condition.
•Maximum attractive force with minimum
potential energy. This is a sufficient condition.
(Chung 1991)
 Peel Adhesion Test

Cotton Cloth
Force
Adhesive

Cast Iron

Peel Speed = 30 cm/min

 Adhesion Values
Average Peel Force (g/25mm) 90.0
80.0 Sample 1
Sample 2
70.0 Sample 3
Sample 4
60.0
Sample 5
50.0
40.0
30.0
20.0
10.0
0.0
0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0
Concentration (% actives)
 Typical Tensile Stress
Low Modulus High Modulus
Weak Brittle
Tough Strong
Tough

Strain Strain
Coating Requirements

• Must form uniform films

• Provide stable adhesion
• Be stable
• Have some re-wettability
• Have controllable hardness
Synthetic Additives

Organics from
Fibers
Inorganic
Salts Thermoplastic
(rewettable)
Thermoset
(cross-linking)
Embedded
Fibers Release
 Kymene
• Good attraction to fibers (cationic)
•Strength increases with heating
•Crosslinking polymer
•Limited wettability
•Provides good dryer protection
•Minimum addition rate for dryer
protection is 0.35 kg/ton
 PVA
• Nonionic (compatible with kymene)
• Good film former
• High cohesive strength
• Rewettable
• Different grades available
•% Hydrolysis
•Molecular Weight
• Typical application amounts: 0.3-2.5 kg/ton
based on tissue grade
 Peel Adhesion
PVA / KYMENE MIXTURES
1,200

1,100

1,000

900

800

700

600
0 10 20 30 40 50 60 70 80 90 100

% Polyvinyl Alcohol (balance kymene)

 Releases
• Modify coating
•Provide lubrication for doctor blade
•Examples
Quaternary Amines - Quaker 2008
Emulsified Oils - Cynol, Mulrex, Houghton
Polyglycol Esters - Hercules M-1336
•Quat. Amines and Esters provide less release
action
•Oils are powerful releases and difficult to
control to correct amount
Dryer Coating Composition
(In order of % of mixture)

What we spray on the dryer -

Water
Polymer A
Polymer B
Release
Inorganic Salts

What is actually in the coating -

Cellulose fiber
Ash?
Polymer A
Polymer B
Inorganic Salts
Release
Water
Coating Application System
Chemicals
Water
Recirculation Line
 Coating Application System
Chemicals
Variable Speed Chemical
Metering Pumps (Gear)
VS VS VS
Mass
FIC FIC FIC Flowmeters

Check Yankee
Pressure Surface
Valves Gauges
Hard Water

In-line Filters (2)Spray Boom & Nozzles

Booster Pump
Mixer
 Metering Pumps

• Inexpensive •More Accurate

Advantages •Infinite speed
adjustment
•Uneven flow, possible • Expensive
hammering in lines
Disadvantages
•Pulsation dampers
needed
 Filters

•Reduces nozzle plugging from:

•Water source
•Undissolved PVA
•Bacteria "slugs"
•Should be placed close to
application
•Progressively finer screens as
you move down steam
•Must be safe and convenient for operator

•Should have:

•Gauge cocks to isolate tips

•Separate cross bars w/individual bodies for each tip
•Removable booms

•Typical set-up: 15 cm apart, 12-20 cm away from yankee,

700 900 kPa supply pressure
 Spray Nozzles

•K-C uses Spraying Systems Unijet® nozzles

O O
•Spray angles range from 65 - 110

•Flowrates range from .025 - .100 gpm

•Nozzle part number tells flowrate and spray

angle at 275 kPa

Example:
8001

80O Spray Angle .100 gpm Flowrate

650050

65O Spray angle .050 gpm Flowrate

Spray Nozzle Geometry
"W"

O/2 O/2

"H"
Spraying Systems Uni Jet Nozzles
100
8001
90
650025
80 6501
70

60 6501
650025
50

40
20 40 60 80 100 120 140 160 180 200
Nozzle Pressure (PSI)
Spraying Systems Vee Jet Nozzles
0.3

6501
0.2

650067

650050
0.1
650033
650025

0 0 20 40 60 80 100 120 140 160 180 200

Pressure (PSI)
Volumetric Distribution of Spray Nozzle
For A New Nozzle
50

40

30

20

10

0
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31
Spray Pattern
Volumetric Distribution of a Spray Nozzle
For a worn nozzle

50

40

30

20

10

0
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31

Spray Pattern
Volumetric Distribution of Spray Nozzle
Double Coverage - New Nozzles

50

40

30

20

10

0
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31
Spray Pattern
Volumetric Distribution of Spray Nozzle
Double Coverage - Worn Nozzles
50

40

30

20

10

0
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31
Spray Pattern
Volumetric Distribution Spray Coverage
Triple Coverage - New Nozzles
40

30

20

10

0 1 5 9 13 17 21 25 29

Spray Pattern
Volumetric Distribution Spray Coverage
Triple Coverage - Worn Nozzles
50

40

30

20

10

0
1 5 9 13 17 21 25 29
Spray Pattern
 Drying Load
(for coating application)

Nozzle Spray Spray Nozzle Total Flow Number of Steam % of Total

Size Pressure Spacing Coverage Flow per Nozzles Consumption Steam Flow
X's Nozzle

(kg/cm2) (cm) (LPM) (LPM) (KG/HR)

6501 8.4 15 2 19.5 0.65 30 656 13.4%

650050 8.4 15 2 9.8 0.33 30 328 6.3%
8001 2.8 23 2 7.6 0.38 20 254 4.8%
650067 8.4 10 3 20.1 0.45 45 674 13.9%
 Spray System
Recommendations
Spray Tips - 650050
O
Coverage - Double Overlap / 5 Offset
Boom - Easily Changeable Tips/Booms
Filters - 70 to 100 Microns
Pumps - Gear Pumps
Mixing - Direct Injection
Water - 100+ ppm Calcium and Alkalinity
Temperature - As is (non heated)
Flow Meters - Micromotion (Mass Flowmeters)
Chemicals - PVA/Kymene/Release
Glass Transition Temperatures of Common
Dryer Coating Chemicals
Adhesive Type Comments T g (C)
poly (aminoamides) Commercial materials
crosslinked
with epichlorohydrin 48-70

polyamides polyacrylamide 165

ployvinyl pyrrolidone 126-174

polyamines commercial ethylene dichloride

alkylamine type -18-20

polyvinyl alcohols commercial 68-75

polyvinyl acetate 28

polyethers polyethylene oxide (PEO) -67

polypropylene oxide (PPO) -75

poly (acrylic acid) 106

cellulose derivatives methyl cellulose 150

ethyl cellulose 43

hemicellulose various types 150-220