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Adding & Preserving Quality - Finishing & Converting

Tissue World Americas 2002. Balbir Singh & Carl Ingalls. Adding & Preserving Quality - Finishing & Converting. Changing Role of Converter. Fluid & Semi- Fluid State. Solid State. P/M Dry End. Wet End. Paper Machine. Converting. Packaging. Crepe Doctor. Solid Mech. Mech. E.

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Adding & Preserving Quality - Finishing & Converting

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  1. Tissue World Americas 2002 Balbir Singh & Carl Ingalls Adding & Preserving Quality-Finishing & Converting

  2. Changing Role of Converter Fluid & Semi- Fluid State Solid State P/M Dry End Wet End Paper Machine Converting Packaging Crepe Doctor Solid Mech. Mech. E. Ind. E. Chemistry Chem. E. Mech. E.

  3. Finishing Processes Calendering Plybonding or laminating Embossing Lotionizing Printing

  4. Finishing in Converting The converter’s domain P/M Dry End Wet End Paper Machine “Converting” Packaging Crepe Doctor Practical location for finishing processes Alternate location for calendering

  5. Why Calender? Handfeel Gain Bulk Reduction Bulk Leveling Bulk Reduction

  6. Calender Nip Crowning Zero-Crown Nip-Control Skewing

  7. Calender Gap Control Load activated For handfeel Against stops Bulk control

  8. Handfeel Quality Curves Gain or loss, relative to the base paper. HF gain More calendering Before calendering Bulk loss More calendering Before calendering Actual values of product properties. Target HF HF Base paper HF Bulk

  9. Finishing Is a Balancing Act Handfeel Bulk Calendering Bulk Strength Embossing Handfeel Absorbency Lotionizing

  10. Process Control Curve – Embossing Base MDT Embossed Bulk Base CDT Embossed MDT Embossed CDT Base Bulk Operating range Nip Line Load (pli) No embossing (base sheet) More embossing

  11. Quality Control Curve – Embossing Target Window Bulk range CDT range Bulk Base paper bulk & CDT (before embossing) CDT

  12. Converter’s Needs Bulk b P P Stretch e F F Strength

  13. Variability Uneven Bulk Tapered Reel Uneven Rolls Uneven strength Poor tracking Sheet breaks Holes & Nicks Sheet breaks Poor quality

  14. Reel Mechanics Tensile Stress Layer Pressure Reel Radius Reel Radius Bulk Nip Pli Reel Radius Reel Radius

  15. Reel Types Secondary Arm Reel Linear Reel

  16. Bulk: Thickness Under Pressure Embossing is not crushed. Embossing crushed, but not crepe. Bulk All 3 sheets crushed. Embossed Creped Flat Pressure

  17. Product Properties How the user will experience the product. • Bulk – fullness, thickness under pressure. • Strength – resist failure during use. • Absorbency – remove liquid. • Handfeel – smoothness, cushion, drape. • Plycount – implies quality. • Visual appeal – implies quality.

  18. Rewinders 2-Nips Weighting/Un-weighting Drum Speed Differential One-Nip One Speed Horizontal Rail Two-Drum

  19. Tissue Winders Center Winder Surface Winder

  20. Folder Transverse Fold Rollers Longitudinal Fold Plows

  21. Combating Tools Bowed Roll Calender Rolls Draw Rolls Dancer Rolls

  22. Grouping Combating Tools Nip Rolls Dancer 1. Unwind Stand Bow Roll Skew Roll Tension Roll Bow Roll 2. Embosser Stand Draw Rolls Embosser

  23. A Diagnostic Tool 0.50 Target Window 0.40 Bulk range 0.30 Bulk CDT range 0.20 Base paper bulk & CDT (before embossing) 0.10 0 0 50 100 150 200 250 CDT

  24. Comparing Embossing Curves 0.50 0.40 Bulk range 0.30 Bulk CDT range 0.20 C A B 0.10 0 0 50 100 150 200 250 CDT

  25. Specifying the Base Paper Window for Base Paper Properties Bulk range Window for Embossed Product Properties Bulk CDT range CDT

  26. Converting • Converting should start at crepe doctor. • Make the reel uniform and soft. • Avoid rewinding. • Match equipment with the product. • Provide necessary combating tools. Finishing • Finishing adds quality during converting. • Focus on end-use properties. • Manage tradeoffs between properties. • Use Finishing Curves: - set base specs - centerline process - diagnose problems Conclusion

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