Crescentformer

Forming Presentation
 Agenda
•1/ Fabric Design:
– Warp Bound Triple Layer (Enterprise)

•2/ Key Operating Variables

– Sheet Trim Method / Fabric Width Considerations
– Operating Tension
– Jet Impingement

•3/ Showering:
– Showering Best Practices
FABRIC DESIGN
 Crescentformer
Forming Fabric Design Criteria

Drainage:
• fabric must be open enough to handle high dewatering loads
• speed, formation, tensile ratio

Fiber Support
• fabric must be fine enough to retain fiber, build sheet
• retention, pin holes, tensile

Stability / Durability
• width stability critical on Crescentformers
• wear potential for life
 Conventional Triple Layer
• in conventional weft bound fabrics, considerable amount of
reported Open Area actually blocked by binder
• no extra binder yarn in Enterprise
• open structure for ease fast dewatering, ease of cleaning

Paper Making Surface

Reported as Open Area

MD
Blocked by Weft Binders
• Enterprise at 450cfm WILL OUT DRAIN other products at +550cfm
 Conventional Triple Layer
• delamination with conventional WEFT bound fabrics limits life
• warp bound Enterprise will not delaminate
• longer life potential

Binder Wear
Weft Binding
 Warp Binding
• take existing bottom MD warp yarn to bind
CDL-4 WEAVE COMPARISON
CDL-4 DAR (Marking)

CDL-4 SAR (Non-Marking)

 Warp Binding
Patented Enterprise Design:
• More Open than conventional Triple Layer and Double Layer designs.
• Faster drainage
• Dryer sheet off the former / machine speed
• Sheet formation (flocs)
• Higher Fiber Support than other designs:
• Fiber retention
• Sheet tensile
• Pin holes / formation
• Better Life potential than other designs:
• No delamination with warp binding
• Excellent wear potential
• Improved width stability with use of comparable weft diameters
Comparison of Specifications
P621 / T521
Conventional Enterprise 2184 - Fine Enterprise 2184 - Coarse
Triple
WEFTLayer
Binding WARP Binding WARP Binding
Mesh - Total (/inch) 188 x 120 184 x 165 184 x 141
Mesh - Top (/inch) 94 x 80 92 x 110 92 x 94
Mesh - Bottom (/inch) 94 x 40 92 x 55 92 x 47
Warps (MD) 0.125mm 0.127mm 0.127mm
Wefts (CMD) 0.15mm 0.11mm 0.13mm
0.11mm
0.25mm 0.21mm 0.25mm
Caliper 0.027" 0.024" 0.026"

Permeability 490 cfm 450 cfm 480 cfm

Open Area 30.0% 36.7% 36.3%
Drainage Index 39.2 DI 49.5 DI 45.1 DI

Frame A (MD x CMD) 0.178 x 0.686mm 0.121 x 0.437mm 0.140 x 0.437mm

Frame B (MD x CMD) 0.178 x 0.145mm 0.121 x 0.155mm 0.140 x 0.155mm
MD Frame Length 0.178mm 0.121mm 0.140mm

Fiber Support Index 138.1 FSI 187.0 FSI 165.6 FSI

Support Points (/inch2) 3760 6600 5640
Stability Benefits - Enterprise

900
800
700
600
500
400 mN
300 mNm
200
100
0
Gemini 2184-Fine Polaris 2184-
Plus Coarse
 Tissue References - The Americas
Machine # Former Width Grades BW Furnish Speed Fabric(Outer)
1 3 CrescentFormer 110 Tissue 9.5-12 Waste 5600 Gemini Plus
2 3 CrescentFormer 254 Tissue/Towel 9.5-27 Kraft 4600 Enterprise
3 3 CrescentFormer 110 Tissue/Towel 9.5-12 Waste 5500 Enterprise
4 9 CrescentFormer 202 Tissue 9.5-11 Waste 5500 Enterprise
5 20 CrescentFormer 280 Tissue/Towel 9.5-15 Waste 5500 Polaris
6 5 CrescentFormer 310 Tissue 9.5-11 Kraft 5600 Polaris
7 1 CrescentFormer 130 Tissue 9.5 Kraft 5500 Enterprise
8 1 CrescentFormer 206 Tissue 9.5 Kraft 5500 Enterprise
9 2 CrescentFormer 210 Tissue 9.5 Kraft 5500 Enterprise
10 18 CrescentFormer 200 Tissue/Towel 9.5-13 Waste/Kraft 5700 Enterprise
11 1 CrescentFormer 80 Tissue 9.5-11 Waste 4000 Enterprise
12 2 CrescentFormer 80 Tissue 9.5-11 Waste 4000 Enterprise
13 3 CrescentFormer 110 Tissue 9.5-11 Waste 5000 Enterprise
14 1 CrescentFormer 172 Tissue 9.5-11 Kraft 5500 Enterprise
15 1 CrescentFormer 172 Tissue 9.5-11 Kraft 5500 Enterprise
16 1 CrescentFormer 132 Tissue 9.5-11 Waste/Kraft 4500 Enterprise
17 2 CrescentFormer 132 Tissue 9.5-11 Waste/Kraft 4500 Enterprise
18 2 CrescentFormer 173 Tissue 9.5-11 Kraft 5500 Enterprise
19 1 CrescentFormer 209 Tissue 9.5-11 Kraft/Waste 5700 Enterprise
20 1 CrescentFormer 220 Tissue 9.5-11 Kraft/Waste 5500 Enterprise
21 2 CrescentFormer 220 Tissue 9.5-11 Kraft/Waste 5500 Enterprise
22 11 CrescentFormer 200 Tissue 9.5-12 Waste 6000 Polaris/Enterprise
23 3 CrescentFormer 140 Tissue 9.5-13 Waste 5500 Enterprise
24 3 CrescentFormer 145 Tissue 9.5-11 Waste 5500 Enterprise
25 1L CrescentFormer 171 Tissue 9.5-11 Waste/Kraft 3500 Polaris
26 11 CrescentFormer 110 Tissue 9.5-13 Waste 5000 Polaris
 Case Study #1
Mill: Midwestern US

Machine: 202” Crescentformer

Grades: 9.5 - 13# (15 - 20 gsm)

Furnish: 100% Waste Furnish (high ash content)

Speeds: 5800 ft/min (1765 m/min)

Fabrics: Enterprise 2184 preferred product

Improved retention and formation
Excellent drainage and wear potential
Improved sheet CMD profile
Trim Beads
 Case Study #2
Mill: Mexican Mill

Machine: 150” Crescentformer

Grades: 9.5 - 13# (15 - 20 gsm)

Furnish: Waste / Kraft Furnish

Speeds: 5750 ft/min (1750 m/min)

Fabrics: Enterprise 2184 preferred product

Excellent formation / tensile
Improved sheet properties over other deigns
Trim Beads
 Case Study #3
Mill: Eastern US Mill

Machine: 210” Crescentformer

Grades: 9.5 - 13# (15 - 20 gsm)

Furnish: 100% Waste Furnish (Low quality, dirty)

Speeds: 5900 ft/min (1800 m/min)

Fabrics: Enterprise 2184 preferred product

Improved drainage / formation
Runs cleaner than other designs
Trim Beads
Defining Sheet
Edges
 Defining Sheet Edges

Not possible to locate Trim Squirt on Forming Fabric,

as is common practice on other Former types:

– Locate Trim Squirt on felt:

• poor sheet edge
• felt filling
– Trim Sheet Using Plastic Fabric Edges

– Trim Beads
 Extruded Edges

•1cm and 1” widths common

• provides a straight inner edge for sheet trim
• protective shield recommended

Headbox

Fabric Edges Fabric

inside Headbox
Extruded Edges
 Sheet Trim – Trim Beads
–at Yankee, Creping Blades see a temperature step
change where sheet ends
– Crepe blade wears at this point.
• if in sheet, edge tears and breaks.
• if in Shaving, reduced sheet breaks and blade changes

Yankee
Sheet on Yankee

Crepe Blade
- No sheet Trim to Yankee - sheet trim to Yankee
- temperature step change at sheet edge - Temperature step change in Shaving
 Trim Beads
5mm
mmm
mmm
mm

Plastic beads extruded inside fabric edges:

 locate 1.5 – 4cm inside fabric edges.
 generates sheet Trim / Shaving
 durable Polyurethane withstands Chemical attack.
Protective Shield

HP Shower Boom

Protective Pan

Fabric (Blue Edge Glue)

OPERATING
VARIABLES
Crescentformer Adjustments
• Jet / Wire Ratio
• Jet Impingement
BR - FR Gap
-25 – 30mm common
- uniform front/back

Fabric Tension

Separation Angle
(3 – 70 common)
 Headbox Considerations
• Consistency: Low = Best Formation (0.1 - 0.3% common)
– Low HB consistencies = higher drainage load on fabric
– No different from other Former configurations

• Jet / Wire Ratio: rushing the jet can “pick” the felt surface
– Limitations on using jet/wire to control tensile
– Increases the benefits of fast draining fabric design

• Jet Impingement Angle: angling too much into felt can result
in “picking.”
– Again, limitations here increase importance of fabric design
– Must be fast dewatering
– At same time, must have high FSI to optimize retention / pin holes
Jet Impingement Angle
Breast Roll
Excessive
Impingement
Angle
Forming Roll

Breast Roll Correct

Impingement
Angle

Forming Roll
Jet Impingement
Measurement
 Fabric Tension
• Dewatering a function of Fabric Tension:
D = T/R
D = Drainage
T = Fabric Tension
R = Radius of Forming Roll

• Use as much tension as is needed to get

desired dewatering rate:
– sheet formation
– CD Tensile (MD/CD Tensile Ratio)

• Typical Tensions 35 - 55 PLI

 WIRE TENSIONING

• Operating Tension:
– single Layer Fabrics - 30 - 40 PLI
– multi-layer Fabrics - 35 - 55 PLI

• Tension Measurement:
– Huyck Tensometer still industry standard.
– different curves for different fabric styles.
– curves for all fabric designs converge above
about 40 PLI.
 Tensiometer
Voith Fabrics Curve
- Tension vs Huyck Reading
140
130
120
110
100
90 Saturn 2184 Avg.
80 Gemini Plus
2164 Avg
70 2164 852 Avg
60 2184 2152 Avg
50 Average Prod. Graph
40
30
20
10
0
PLI 5 10 15 20 25 30 35 40 45 50 55 60

Avg. 28.857 56.429 75 83.714 90.857 96.75 102.5 107.5 107

Avg 40.359 59.897 75.436 84.872 93.04 98.877 103.13 107.49 111.76 113.86 117.17
SHOWERING
 Typical Showering

• Inside HP Fan (150 – 250 psi)

• HP Needle (350 - 500 psi)

– Face Side preferred

•Flooded Nip Shower (Volume)

• Edge Showers

• Barrier Chemical Shower

– Application Rate (ml / min)
– Need for Caustic Stripping
Showering – Best Practice

Chemical
Shower

HP Fan
HP Needle Shower Flooded Nip
Showering – Best Practice

Chemical
Shower

HP Fan
Flooded Nip HP Needle Shower
 Needle Showering
Inside or Outside ?

Typical Stickie
- paper side of fabric
- forms at yarn cross-overs

- blind to Inside HPS

- inside HPS even less

effective with multilayer
fabrics
 Needle Showers
Effective Against Stickies

Typical Stickie
- need HP Needle
 Needle Showers
Distance from Fabric

Effective
Cleaning
Distance
0-4” 4-8” Beyond 8”
Needle Showers
Location to Rolls

Locate close to Roll

- support fabric
2 - 5” Common
- wasted shower pressure
- fabric damage
Needle Showers
Angle to Fabric

Angle into Fabric Run Direction

- OUTSIDE HPS
- maximize impact energy
- “chisel” contaminants”

10 – 20o
 Needle Showers
Damage to Fabrics

Excessive Pressure

Poor Oscillation
 Needle Showers
Damage to Fabrics
Macro view of High-Pressure damage to fabric surface
Flooded Nip Shower
Fiber Contamination

Typical Fiber Carryback

- High Pressure Fan
- Flooded Nip
 Flooded Nip Showering
Volume Calculation

RVV = C x W x S x V
C = fabric caliper (inches)
W = fabric width (inches)
S = fabric speed (ft/min.)
V = fabric percent void (use 0.6)

* 100% of RVV not needed, depending on speed of machine.

At +5000 ft/min, as little as 70% of RVV can be effective.
 Chemical Showering

Rate of Application:
• can not add faster than chemicals being worn off by HPS
• uniform application (shower nozzle conditions)

apply cleaning chemicals:

Solvents
Caustic wash-ups
• effect on fabric monofilament
• effect on extruded edges / Trim Beads
 Fabric Life
Considerations
FORMING FABRIC LIFE
• Normal Failure Points
– Wear
• Roll Side or Sheet Side
• Caliper Loss Measurements
• Seam Issues (single layer designs)

• Typical Life
– Single Layer: 45 - 75 days
• stability issue / seam issues
– Multi-layer Designs:+75 days
• Damage most common limitation
 Wear Profiles

AMERICAN TISSUE ST. HELENS, OREGON

MACHINE #3-CRESCENT FORMER
ORIGINAL
CALIPER (INCHES)

.0240 USED
.0230 SAFE WEAR
.0220 #15531
.0210
.0200
.0190
.0180
.0170 FRONT
.0160
.0150
18

36

54
72

90
0

108

126

144

162

180

198

216
234

252
WIDTH (INCHES)
Hour-Glassing
 Drag Wear

MD

Wear Burrs on trailing edge of CMD knuckles

 Roll Wear

Wear Burrs on all sides of CMD knuckles

Roll corrugation probable