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Tissue Properties and Manufacturing Forming and TAD Fabrics Peter McCabe Tissue Business Leader AstenJohnson

Tissue Properties and Manufacturing Forming and TAD · PDF fileTissue Properties and Manufacturing Forming and ... the forming fabric design Productivity– Machine speed, breaks

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Page 1: Tissue Properties and Manufacturing Forming and TAD · PDF fileTissue Properties and Manufacturing Forming and ... the forming fabric design Productivity– Machine speed, breaks

Tissue Properties and Manufacturing

Forming and TAD Fabrics

Peter McCabeTissue Business Leader

AstenJohnson

Page 2: Tissue Properties and Manufacturing Forming and TAD · PDF fileTissue Properties and Manufacturing Forming and ... the forming fabric design Productivity– Machine speed, breaks

Forming Fabrics

Page 3: Tissue Properties and Manufacturing Forming and TAD · PDF fileTissue Properties and Manufacturing Forming and ... the forming fabric design Productivity– Machine speed, breaks

3‐ Slide 3

““THE FORMING FABRICS ARE THE MAJOR INTERFACE BETWEEN THE THE FORMING FABRICS ARE THE MAJOR INTERFACE BETWEEN THE STOCK JET AND THE MECHANICAL ELEMENTS FORCING DRAINAGE TO STOCK JET AND THE MECHANICAL ELEMENTS FORCING DRAINAGE TO

OCCUROCCUR””

Outer FabricOuter Fabric

Inner FabricInner Fabric

STOCKJET

Impact Paper Machine and Fiber Efficiency as well asFinal Sheet Quality

FORMING FABRICS THEREFORE

Role of Forming Fabrics on Tissue Production

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4‐ Slide 4

Role of Forming Fabrics on Tissue Production

Stock Drainage – Take fiber from head box consistency of 0.05 – 0.50% and deliver sheet to pick‐up / transfer at 8‐25%

Provide Fiber Support – Build uniform sheet, desired sheet properties, and first pass retention

Efficient Machine Operation – Drainage rate, fiber and water carry back, cleanability, and drive load are all impacted by the forming fabric design

Productivity– Machine speed, breaks, sheet transfer, holes all impact the machine production efficiency

Energy Use – Higher solids to pick‐up and uniform drying

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5‐ Slide 5

Role of Forming Fabrics on Tissue Production

Sheet Properties – The forming fabric will impact

Directly•sheet formation, •sheet profiles (CD and MD)•Tensile strength •Fiber orientation •mechanical retention

Indirectly ‐ uniformity of the sheet delivered to the crepe blade•Sheet softness•Bulk •Stretch•Absorbency

Page 6: Tissue Properties and Manufacturing Forming and TAD · PDF fileTissue Properties and Manufacturing Forming and ... the forming fabric design Productivity– Machine speed, breaks

6‐ Slide 6

Forming / TAD Fabric Terminology• Monofilament Strand – Forming / TAD fabrics are woven 

on a loom from extruded plastic yarns.  Modified polyester is the most common material but other materials, such as nylon, are also used

• Strand Size – 0.10 mm to 0.45mm most common in Tissue Fabrics

• Warp  – The machine direction (MD) strands.

• Weft (shute) – The cross machine direction (CD) strands.

• Mesh – The number of MD strands per unit area (inches or cm).

• Count (knock) – The number of CD strands per unit area (inches or cm).

• Weave – The design of the pattern in the fabric

• Shed Pattern– The repeat pattern in the design

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78/22/2011 ‐ Slide 7

Forming / TAD Fabric Terminology

• Drainage Area %  ‐ The percent open area on the sheet side of the fabric.  Can also calculate mid‐plane and machine side DA for multi‐layer fabrics

• Frames Count – The number of holes per unit area in the sheet side of the fabric

• Support Points – The number of knuckles per unit area on the sheet side of the fabric

• FSI – Fiber support index.  Calculation used to indicate how well the fibers are supported on the sheet side of the fabric.  Can compare similar designs only.  Has limitations on complex double and triple layer fabrics

• Maximum Frame Length – Distance between CD strands on widest MD drainage hole

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8

Forming / TAD Fabric Terminology

• Caliper‐ The thickness of the fabric• Void Volume – The amount of space in a volume of fabric that is not 

occupied by solid material.  Can affect water carry of a fabric. Void volume is used to calculate the require flooded nip water required to flush a fabric.  

• Elastic Modulus – The resistance to stretch in the MD direction.  Important for fabric stability

• Air Permeability – Measure of air flow through a fabric at a standard area and pressure drop.  Normally listed as cfm.  Not an indicator of drainage rate on fabrics of different designs.

• Drainage Index – Design as a tool for determining relative drainage rate of a fabric design.  Effective for single layers but not double or triple layers as the mid‐plane and bottom layers are not involved in the calculation.

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9

Fabric Design Selection

Considerations Parameters

Weave % Drainage AreaMaterial Air Permeability    Mesh/Count Maximum Frame LengthStrand Diameter  Frames count & Shape

Elastic ModulusCaliper – Void VolumeFiber Support Index Cleanability

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10

PAPER PAPER MACHINE

• Grade of Paper • Type and Manufacturer• Type of Furnish • Size (width and length)• Weight Range of Product • Speed Range• Wire Mark Considerations • Type of Pickup

• Head box Flow Rate• Operating Tension• Take-Up Length• Fabric Run History• Shower Set Up

Machine Design Considerations

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11

• Same fiber, same fabric, same method…different results.

Fiber Support ‐ The Critical Difference

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128/22/2011 ‐ Slide 12

Forming Fabric Design Construction

• Single Layer ‐ have One MD Yarn and One CMD Yarn.

• Double Layer ‐ have One MD Yarn and Two CMD Yarns.

• 2.5 Layer ‐ have One MD Yarn and Three CMD Yarns.

• Triple Layer ‐ have Two MD Yarns and Two or Three CMD Yarns Depending on the Method Used to Bind the Two Layers of the Structure.

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138/22/2011 ‐ Slide 13

Single Layer Profiles  

5 Shed, 1,4CD

MD

5 Shed, 2,3CD

MD

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148/22/2011 ‐ Slide 14

Double Layer Profiles  

8 Shed MDCD

CD

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158/22/2011 ‐ Slide 15

2.5 Layer Profiles  

7 Shed MD

CD

CD

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168/22/2011 ‐ Slide 16

Triple Layer Profiles

C D

M D

Plain Weave-Top

4 Shed Bottom

C D

M D

3 Shed Top

4 Shed Bottom

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178/22/2011 ‐ Slide 17

Single Layer(OT 20‐35 PLI)

Advantage• Lowest Cost

• Easy to Clean

Disadvantage• Low Fiber Support

• Low Durability

• Low Seam Strength

• Limited Designs

Forming Designs and Applications

Double Layer(OT 25‐50 PLI)

Advantage• Higher FSI

• Good Stability

• Longer life

• Improved Retention

Disadvantage• Higher Cost

Triple Layer(OT 30‐80 PLI)

Advantage• High Drainage

• High formation

• Most Durable

• High Retention

• High Stiffness

Disadvantage• Higher Void volume

• Higher Cost

Page 18: Tissue Properties and Manufacturing Forming and TAD · PDF fileTissue Properties and Manufacturing Forming and ... the forming fabric design Productivity– Machine speed, breaks

18‐ Slide 18

Trends In Tissue Forming FabricsTriple Layers ‐ Dominant Tissue Design

Triple Layer Advantages

•Ability to have fine sheet side and durable machine side•Engineered drainage potential 

Can control drainage rate with weave designHigh drainage rate potential – straight through drainage

•Increased mechanical retention

•High fabric stiffness and width stabilityReduced CD profile variationStable width for use in Crescent formers with trim beads

•Long life potentialLarge machine side wear strandsDurable and damage resistant

•Easy to cleanExcellent shower penetration – with straight through drainage holes

Page 19: Tissue Properties and Manufacturing Forming and TAD · PDF fileTissue Properties and Manufacturing Forming and ... the forming fabric design Productivity– Machine speed, breaks

19‐ Slide 19

Tissue Forming Fabrics – Position ApplicationTriple Layers 

• Twin Wire Outer positions – Stiff, fast drainage, high support

• Inner positions suction roll – Thin, high support

• Crescent Formers – Stiff, width stable, high support

• SBR – Thin, fast draining, high support, low water carryDouble Layers 

• Twin wire Inner positions – Support and durability

• SBR – Ultra Fine, thin, high support

Single Layers• Inner position transfer fabrics

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208/22/2011 - Slide 20

Page 21: Tissue Properties and Manufacturing Forming and TAD · PDF fileTissue Properties and Manufacturing Forming and ... the forming fabric design Productivity– Machine speed, breaks

218/22/2011 - Slide 21

Tissue Triple Layer DesignsIntrinsic Weft Tied (SSB)

• High Drainage Rates•Superior CD Profiles – High Stiffness•Higher Caliper•Best Dimensional Stability•No Delamination•Strong Seam

Warp Interchange / Warp Tied•Reduced Fabric Caliper•Lower Drainage Rates•No Delamination•Efficient to Manufacture – Lower Cost

•Conventional Tied •Prone to Delaminate

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228/22/2011 - Slide 22

Tissue Triple Layer Designs 

3-Shed Top, 4-Shed Bottom Weft Tied SSB Triple Layer

Tissue Forming Fabric

Machine Side

Sheet Side

Pair of Intrinsic Weft Yarns 

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238/22/2011 - Slide 23

Tissue Triple Layer Designs

Sheet Side

Pair of Intrinsic Weft Yarns 

Intrinsic Weft Tied (SSB) Warp Interchange / Tied

Tie Strands

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248/22/2011 - Slide 24

Tissue Triple Layer Designs

Sheet Side

Pair of Intrinsic Weft Yarns  Tie Strands

Intrinsic Weft Tied (SSB) Conventional Tied

Page 25: Tissue Properties and Manufacturing Forming and TAD · PDF fileTissue Properties and Manufacturing Forming and ... the forming fabric design Productivity– Machine speed, breaks

25

Twin Wire Former

‐ Slide 25

Fabric Requirements

Outer Position:

Fast Drainage

High Fiber Support

High Fabric Stiffness and Stability

Low Fabric Stretch

Easy to Clean

Inner / Backing :

Easy to Clean

Low Fabric Stretch

Good Durability for Life

High Fiber Support 

(c‐wrap TAD and Suction)

Stretch

Guide

Stretch

OUTERINNER(CONVEYING) (FORMING)

Guide

INNER (BACKING)

OUTER (FORMING)

Stretch

Guide

Stretch

Page 26: Tissue Properties and Manufacturing Forming and TAD · PDF fileTissue Properties and Manufacturing Forming and ... the forming fabric design Productivity– Machine speed, breaks

26

Crescent Former

Fabric Requirements

Width Stability – Sheet Width Control

High Fabric Stiffness – CD Profile

Fast Drainage – High Speed Operation

High Fiber Support‐ Formation and Retention

Low Fabric Stretch – High Tension Operation

Easy to Clean – Efficient Showering

Low  Water Carry back – Dry Return Run

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27

Fabric Requirements

Fast Drainage – Very Short Forming Zone

High Fiber Support – Formation and Retention

Low Caliper – Drainage and Showering

Fabric Durability ‐ Life

#1

#1

#2 #2

#1

Suction Breast Roll Former

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28

Forming Fabric Production Processes

Yarn Storage Warping Weaving Inspection

Heat Setting Relaxation Cutting

SeamingFinishing Packing / Shipping

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29

Strand spools

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30

Can Warper

Creel

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31

Single beam warp8” Cans

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Page 33: Tissue Properties and Manufacturing Forming and TAD · PDF fileTissue Properties and Manufacturing Forming and ... the forming fabric design Productivity– Machine speed, breaks

TAD Fabrics

Page 34: Tissue Properties and Manufacturing Forming and TAD · PDF fileTissue Properties and Manufacturing Forming and ... the forming fabric design Productivity– Machine speed, breaks

34

TAD Fabric Designs

M‐Weave

G‐Weave

Multi‐Layer Shaping

Page 35: Tissue Properties and Manufacturing Forming and TAD · PDF fileTissue Properties and Manufacturing Forming and ... the forming fabric design Productivity– Machine speed, breaks

35

TAD Fabric Designs

• Most conventional TAD fabrics are based on 5‐shed, single layer, 44 mesh warps

• 36 and 50 mesh warps also used• M‐weave used most on Bath Tissue• G‐Weave used most on Towel• New Multi‐layer Shaping designs entering market

Page 36: Tissue Properties and Manufacturing Forming and TAD · PDF fileTissue Properties and Manufacturing Forming and ... the forming fabric design Productivity– Machine speed, breaks

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44 M‐Weave

Machine SideSheet / Yankee Side

Used Primarily for Bath TissueMedium bulk generation

Good softness

Page 37: Tissue Properties and Manufacturing Forming and TAD · PDF fileTissue Properties and Manufacturing Forming and ... the forming fabric design Productivity– Machine speed, breaks

37

44 G‐WeaveUsed Primarily for Towel Production

Increased bulk generationMachine SideSheet / Yankee Side

Page 38: Tissue Properties and Manufacturing Forming and TAD · PDF fileTissue Properties and Manufacturing Forming and ... the forming fabric design Productivity– Machine speed, breaks

38

Sheet / Yankee Side

Multi‐Layer Shaping

Customize sheet impressionAble to develop increased bulk and softness

Increased durability and life potential

Page 39: Tissue Properties and Manufacturing Forming and TAD · PDF fileTissue Properties and Manufacturing Forming and ... the forming fabric design Productivity– Machine speed, breaks

39

TAD Seam Development

• New Technologies able to increase seam strength and reduce seam width

• Seam no longer limiting factor for weave design or fabric life

• Laser Welding• Ultrasonic Welding

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40

Benefits of Laser Welding for TAD 

•Significant increase in seam strength

•Reduce seam width by 50‐ 70%

•Seam area permability consistant with body of fabric

• Design Flexibility Seam strength no longer consideration in weave designCustomize weave to produce unique pattern in sheet

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Glue vs. Laser Weld

Air perm in the glued seam area is averaged 480cfm and 590cfm in the cloth area. 

Glue vs. Weld

Glue vs. Weld