aic proprietary & confidential david bates - albany · 2019-11-20 · disclosing this document...

© 2018 Albany International Corp. — Distribution subject to the restrictions on the first page

AIC PROPRIETARY & CONFIDENTIAL

1

David Bates - Albany

Ingeniero en Ciencia del Papel por la SUNY ESF (Colegio deCiencias Ambientales y Forestales) de la Universidad de NY.

Experiencia en la fabricación de papel por 26 años

James River Corporation – Especialidades

Packaging Corporation of America – Kraft

Gaylord Container – papel Bolsa & Liner

Ventas de químicos por 2 años

Ashland Chemical

Albany International, Ing. de Ventas y Servicio 3 años

Albany International, Gerente de Aplicación de "Mangas paraPrensas con Zapata" – 4 años

Todos los segmentos: Tissue, Empaque, Escritura eimpresión, Pulpa



www.albint.com | AIN | #albint

This document contains proprietary, confidential, and/or trade secret information of Albany International Corp. (“AIC”). Possessing, using, copying ordisclosing this document to or for the benefit of any third party without AIC’s prior written consent may result in criminal and/or civil liability.

©2018 Albany International Corp.

Tissue Round Table – November 2019

Tissue Shoe Pressing Trends 2019



3

Agenda

Tissue shoe pressing comparisons

Tissue shoe press Felt-Belt Interaction

Belt Resin choice (modulus vs hardness)

Belt Void Volume choices

Shoe press Best Practice

Shoe Press Promises:

• Wider range of pressing conditions in linear load and nip pressure MD profile

• Uniform press nip CD profile resulting in:

• Uniform post press sheet moisture profile

• Uniform coating

• Uniform creeping

• Lower operational cost







Tissue Shoe Pressing Comparisons



5

Tissue Shoe Pressing Development



6

1999 Tissue machine layout

Crescent former. Suction turn roll

Shoe Press

Yankee

Crepe Reel

Shoe press is placed against the yankeecylinder – this provides unique challenges

for operation

Suction press roll replaced by suction turning roll and shoe press added against the yankee

Issues:

• Yankee may have to be rebuilt or replaced to handle the load

• Ribbed Yankees were common



7

Yankee cylinder and shoe pressing

• The Yankee cylinder behaves very differently to a standard counter roll

• The hot surface deforms during operation

• Amount of deformation depends on machine speed, operating temperature, amount of condensation on Yankee inner surface, steam pressure, shoe material, etc.

• If the Yankee steel shell has to be reinforced (increasing it’s shell thickness) the main benefit of the steel Yankee Dryer can be lost

• The shoe on a tissue shoe press is much shorter than a normal shoe, approx. 150 mm

• All of these factors mean a tissue shoe press operates under very different conditions to a normal shoe press

Voith was first with a few claimed benefits:

• 15% increase in production

• Sleeve change accompanies other clothing changes

• Lower Pmax on felt provides lower felt compaction

• No new drive capacity needed

• Fairly quick payback

Problems encountered:

• Yankee is wider than the shoe, the shoe edge load zone is prone to problems such as felt compaction, belt wear and cracking



8

Concerns with design transferred to sleeves

• In theory the flexible shoe can bend to match the yankee but under operating conditions as temperature and pressure gradient builds the shoe can flex down as the yankee expands.

• The yankee heads expand in a radial fashion as compared to the rest of the yankee

• This creates a very harsh condition for the shoe edges of the sleeve resulting in wear and/or cracking



9

2006 Multi-Chamber design (Valmet ViscoNip™)

Not pressurized Pressurized

• Pressure against the yankee is delivered by several membrane blocks

• Achieve linear loads of 80 – 160 kN/m or even higher in some cases

• Yankee must be able to handle the load

• Provides flexibility in distributing the load



10

2013 on new machine concepts

TransBelt – texture sheet

Shoe press – dewatering & bulk

Shoe press is moved away from the yankee and a transbeltused as a transfer medium and to texture the sheet

• Load is now applied to a counter roll via a shoe press

• Yankee is no longer responsible to endure the load and can be designed for maximum heat trasfer

• Loads of 500 – 600 kN/m



11

Avaliable machine concepts

AndtrizPrimePress

Toscotec TT NextPress

• Flexible systems, can run different clothing set ups

• HARD NIP

Nipcoflex T

Valmet NTT

Valmet Visconip

• SOFT NIP

Gapcon ERS Prepress

Various concepts sold for different outcomes;

• Load flexibility

• Simplicity of operation

• Flexible configuration

• Lower cost of operation

• Bulk

The key here is to realize maximum value



12

Belt failure reasons







Tissue shoe press Felt-Belt Interaction



14

Dewatering on a tissue shoe press

• Even profile from forming section is very important

• Dewatering at the suction turning roll is critical for press performance

• Too little dewatering – sheet crushing and edge lifting

• Too much dewatering – no hydraulic pressure and low sheet dryness

• Correct vacuum needs to be applied for best performance (changes as felt breaks in and life extends)

0

20

40

60

80

100

120

140

160

180

200

0.00 0.50 1.00 1.50 2.00 2.50 3.00

Dewatering speed l/s.m

gsm

/fe

lt

HSPG

1st press

1st press

HSPG

1st press

1st press

Core Board

HSPG 3rd press

TissueKraft 3rd press



Key dewatering points

• Function of Suction Turn Roll is crucial to machine performance

• Scanpro suggests some 230-330 gsm Water difference between ex FR and ex nip

• Ecoflow calculation suggests 220-275 gsm removed at the STR

• 10 – 55 gsm difference must be removed via sleeve + felt from the nip

• For a given vacuum zone length, an increase in vacuum does not necessarily lead to improved nip dewatering –if the felt is too dry, no hydraulic pressure

• A thinner, more compressible (less compaction) structure assists with this process,

CRITICAL ISSUES

• Design and condition of sleeve

• Wire width/sheet width in relation to shoe width

• Vacuum balance and control

• Felt moisture balance crucial to give good dewatering

• Additional dewatering box prior to S.T.R. not successful

• Coating package needs to be stabilized

• Purge shower + blade may need to be installed on sleeve







Belt Void Volume Choices



How do grooved belts work?

0

10

20

30

40

50

60

70

80

1 2 3 4 5 6 7 8

Peak Nip Pressure (MPa)

Wate

rflo

wl/m

in m

Blind Drilled

Blind Drilled/Grooved

Medium Grooved

Standard Grooved

High Void Grooved

• It is really important to use resins, groove shapes and void volumes that optimize this dewatering at high rates



Grooved vs. Blind Drilled

1500

1525

1550

1575

1600

Blind Drilled Grooved

1560

1600

Sp

eed

(m

/min

)

40

42

44

46

48

50


44

49

Dry

ness (

%)

5

6

7

8


7.5

6.3S

team

Pre

ssu

re

(bar)

375

400

425

450


450

400

Ho

od

Tem

p (

oC

)

Results from 1st grooved belt to run on TissueFlex machine -16.5g/m² tissue. (Belt Facts #1)

2.6% Speed Increase

11% Hood Temperature Reduction

5% Dryness Increase

16% Lower Steam Pressure



19

Case study – Void Volume

Welc

om

e to A

lbany

Inte

rnational

• Crushing, poor dryness from press section, Holes in the sheet

Solution:

• Improved dryness, no crushing and sheet holes

• Ran 585 days

Initial design 290 cc/m2

Next belt 410 cc/m2

Initial design thought process: Tissue is very low grammage, loading is low so low void volume is needed



20

Tissue belt design evolution

1st trial Optimization Latest optimization

• U groove shape

• 290 cc/m2 void volume

• Many issues on machine:

• Crushing

• Poor dewatering

• holes

• U groove shape


• Good performance

• Standard ViscoNipdesign

• E groove shape


• Developed for NipcoFlex T machines

• Standard design in Europe and USA



21

Groove closure under load

U grooves

E grooves

• Groove Void and design have a very high impact on dryness/bulk

• BD much higher VV but no dynamic water flow

• Voith and Albany belts may have the same VV but Albany groove shape better for retaining open area under load

• Use this as a tool to optimise machine performance



22

Albany resin options

T2

T1

T0B4

Cra

ck G

row

th

Modulus

Resin notes:

• All resin developed by Albany International

• Resins designed for demanding conditions of modern paper machines

• Various hardness values available to suit all applications

VENTABELT XTS

VENTABELT XTR

VENTABELT XT



XT Case Histories

23

• Irving St John TM.2

• 16-22 gsm Virgin Tissue & Towel

• Kraft hardwood eucalyptus bleached, Kraft hardwood Tropical Bleached, Softwood Northern Bleached, Softwood Southern Bleached

• Voith Nipcoflex T, 1st Press 1100mm, 6.3m wide

• 1900 m/min, 150kn/m

1. Sleeve: Trial sleeve removed at 95 million cycles. Very slight micro-cracking at the edges, and only a couple score marks on the inside surface of the sleeve. Looks excellent. Probably could have ran 140-150 million cycles. Very good run with this e-groove trial, saw a 2 point improvement in bulk which is excellent.

Belt 30493442-10 30527347-20Caliper (mm) 5.7 5.79Groove Width (mm) 0.94 1.38Land Width (mm) 2.31 1.83Groove Depth (mm) 1.48 1.5Void Volume (CC/sqm) 402 527Open Area (%) 29 42.1Hardness (C) 70 72Groove type U E



XT Case Histories

• Fujian Hengli TM.2

• 16-22 gsm Virgin Tissue & Towel

• Kraft hardwood eucalyptus bleached, Kraft hardwood Tropical Bleached, Softwood Northern Bleached, Softwood Southern Bleached

• Valmet Visconip, 1st Press 1095mm, 6.95m wide

• 1900 m/min, 150kn/m

• Another record for XT on this double wide 1800m/min Visconip press making toilet tissue.

• Longest ever running belt on a Visconip press

• Belt 30481194-10 has now been on the machine for over 600 days and is still running

• Beats previous best (also XT) of 536 days.

24

0

100

200

300

400

500

600

700

Blackbelt XT XT XT

Blackbelt XT XT XT



XTS Case Histories; Tissue

• Sofidel Wernhausen 2. Germany

• 15-23 gsm Virgin Toilet Tissue

• Voith Nipcoflex T, 1st Press 1100mm, 3.72m wide

• 1800 m/min, 150kn/m

• Run wide variety of loads, 85 – 135 kN/m up to 150

• Average for press is 104 days

• XTS averages 163 days and performs well across operating range

• “Hard” resin introduction has seen big shift in life

• Will move to higher void volume

25

Row Labels Average of Run Days

2-B 1ST PRESS, TISSUEFLEX 104

VENTABELT XTS 163

Qualiflex G 149

VENTABELT XT 92

Qualiflex BD 87

IX F 78

Blackbelt 50

Hard resin average 154

Other resin average 76







Shoe Press Best Practice



Belt Wear

• ViscoNip rebuild machine and the only ViscoNip with a wear problem.

• Normally belts run for >365 days on ViscoNip machines but on PM1 just about 180 days. After that the belts are worn out and got stress cracking.

• Machine is wearing the felts and after that the felts are wearing the belts.

• Customer tried alternate belts, they were far worse for wear



28

• The pin fixing the axis of the ShoePress was bent,

• The pin housing was unlocked, causing a 15 mm misalignment.

Alignment key issues



Tension Equilibrium

• Felt Tension increases and decreases Every Fabric Revolution

• A Tension Equilibrium Exists

• Tension "Spot Checks“

In a shoe press you have additional drive and Brake elementsX Driven press roll (s)

– Driven UN NIPPED ROLL

– Driven felt roll (helper drive)

– Driven forming roll - on Crescent Formers

Brake elements

– Pick-up shoe

– Uhle boxes

– Tissueflex NIP LOAD



Increasing and balancing felt tension

Felt Tension Balance. T 4: FE= 3.0

All Values are kN/m Profile: F/E. 2.7 / 3.0 / 3.2 / 3.3 / 3.0 / 3.0 / 3.1 / 3.0 / 2.9 / 2.8 / 2.6 B/E.

T 3:

F.E. = 1.4 15 inHg

57/58 psi

19 inHg

58/58 psi

High 14.5 inHg

Low 10.0 inHg

T 2: 18 inHg

F.E. = 3.1

T 1:

F.E. = 2.8

Date: 04/04/2002 Grade:

Speed: 1500 m/min. Grammage: gsm @ % Moi.

3

9

1

8

5

2

6

7

2

1

4

Felt Tension Balance. T 4: FE= 3.3

All Values are kN/m Profile: F/E. 3.2 / 3.3 / 3.5 / 3.5 / 3.6 / 3.6 / 3.4 / 3.3 / 3.2/ /3.2 / 3.0 B/E.

T 3:

F.E. = 2.5 11 inHg

57/58 psi

13.5 inHg

58/58 psi

High 12.5 inHg

Low 7.0 inHg

T 2: 14.5 inHg

F.E. = 3.5

T 1:

F.E. = 3.6

Date: 04/04/2002 Grade:

Speed: 1480 m/min. Grammage: gsm @ % Moi.

3

9

1

8

5

2

6

7

2

1

4

• Improved runnablity and speed potential

• Improved dewatering at shoe and Suction Turn roll

• Improved CD profiles

• Cleaner felts

• Better drive balance



31

Summary

Tissue shoe pressing has changed dramatically

Tissue shoe press Felt-Belt Interaction optimizes performance

Belt Resin choice (modulus vs hardness) depends largely on application

Shoe press Best Practice is critical

Gracias!



32

Albany shoe belt styles

• Standard style for ViscoNip presses

• All diameters

• Europe & China manufacture

• Standard style for NipcoFlex T presses

• Selected diameters

• Europe manufacture only

• Newest product platform

• No tissue trials yet

• All diameters

• Europe & China manufacture



Water Flow as Function of Groove Width

Belt Belt + Press Felts

0

20

40

60

80

100

0,6 0,7 0,8 0,9 1

Groove Width [mm]

Wate

r F

low

[l/

m*m

in]

0

5

10

15

20

25

0,5 0,6 0,7 0,8 0,9

Groove Width [mm]W

ate

r F

low

[l/

m*m

in]

+Single layer felt

+2 Layer-felt

+(1+2 )felt



The future; Grooved vs. EVM

36

38

40

42

44

46

48

50

0 1 2 3 4 5 6

Sh

eet

Dry

ness (

%)

Peak Pressure (MPa)

Grooved

EVM

7.0

7.5

8.0

8.5

9.0

9.5

10.0

10.5

0 1 2 3 4 5 6

Bu

lk (

m³/

kg

)*1000

Peak Pressure (MPa)

Grooved

EVM

Results from Metso ViscoNip pilot trials.



35

Life statistics NTT shoe press

-

20

40

60

80

100

120

140

160

180

200

A B C

Life average by supplier

0

50

100

150

200

250

300

Damaged Scheduled

Damaged vs Scheduled

22 16



XT Case Histories; Tissue

• Metsa Raubach PM.1

• 16-22 gsm Recycled Tissue & Towel

• Valmet Visconip, 1st Press 1095mm, 3.99m wide

• 1900 m/min, 150kn/m

• XT belt after 300 days…excellent condition

36

aic proprietary & confidential david bates - albany · 2019-11-20 · disclosing this document...

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