aic proprietary & confidential matt bryer - albany · aic proprietary & confidential 1 matt...
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© 2019 Albany International Corp. — Distribution subject to the restrictions on the first page
AIC PROPRIETARY & CONFIDENTIAL
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Matt Bryer - Albany
Matt es Gerente de Producto de Fieltros Tissue –Americas, responsable técnico y de aplicación de fieltros Tissue en Norte y Sud América.
En 2003 inicio su carrera en el área de R&D en Albany International estando por un año cuando fue incorporado al área de diseño por otros 15 años. Se convirtió en gerente de Producto en 2012.
Matt es Ingeniero Eléctrico del Instituto Politécnico de Rensselaer, radica en Carolina del Sur, EUA.
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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.
©2019 Albany International Corp.
Matt Bryer, Product Manager - Tissue Press - Americas
New Press Fabric Technology and Application
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Discussion Topics
New Press Fabric Technology for the Americas (North America + South America) Seamed
Endless
Advanced
New Enhancement
Shoe Press Application Updates
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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.
©2019 Albany International Corp.
Update on Seamed Technology
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Drivers for Albany Seamed Press Fabric Growth
Secondary Benefits Included Faster Installation and Less Manpower Needed During Installation
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Seamed Press Fabrics for Tissue - Growth
• Seamed Press Fabrics in Tissue were a very small part of the market going back to 2010.
• Based on the success of Albany’s new Seamed technologies, our % product mix for seams in Tissue has more than quadrupled from 2010 through H1 2019
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Albany Seamed Press Fabrics By The Numbers….2011 – H1 2019
8.4
1850
$6MM+
Widest Tissue Machine (meters) running Albany Seamed Fabrics
Fastest Tissue Machine Speed (mpm) running Albany Seamed Fabrics
The amount in documented value savings associated with Albany Tissue Seamed Fabrics
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Documented Value
Albany Seamed Fabrics have documented value in many categories including those listed below: Improved Safety
Improved Drying
Increased Production
Longer Life
Reduced Down Time
Reduced Chemical Costs
Improved Machine Efficiency
Improved Converting Efficiency
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Albany Seamed Fabric Evolution
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BENEFITS
• Steady-State Pressing
• Compaction Resistant
• Superior Water Removal
• Improved Sheet Solids
• Eliminates Marking
• Increased Durability
• Faster Installation
FEATURES
• Micro Seam Technology
• Open, conditioning responsive
structure
• Planar Pressing Surfaces
• High Density Yarn Structure
• Single Monofilament in MD and CD
The Seam PressPlane 2 is the next advancement of seamed
press fabrics for the Tissue Industry. Seam PressPlane utilizes
improved weaving technology to provide a more uniform base
fabric construction, more uniform loop geometry and better
product consistency. Like the SeamPlane, Seam PressPlane
offers a unique laminated base fabric for improved water
removal and sheet solids. The single mono yarns and
laminated structure provides long life potential.
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Upgrades with Seam Pressplane 2
• Big focus on overall fabric and seam uniformity
• Opportunities for even smaller seam loop size to minimize seam marking
Base Fabric Pressure Uniformity Seam Loop Uniformity
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Improved Pressure Gradient
MPa
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Uhle Box Cover Design - Seams
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BENEFITS
• Steady-State Pressing
• Superior Water Removal
• Improved Sheet Solids
• Increased Durability
FEATURES
• All Single Mono Base Fabric
• Planar Pressing Surfaces
• High Density Yarn Structure
• Small Diameter CD Yarn for Ease of Installation
The PressPlane 2 is an endless version of the SeamPlane II that utilizes Albany’s next generation of weaving for improved product quality and pressure uniformity. The all single mono construction provided outstanding cleanability and compaction resistance for long life potential. The CD yarn is selected for ease of installation.
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Cross Section of PressPlane 2
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Benefits of PressPlane Base Structure
More open structure for: • Better drainage
• Easy to clean
Base Permeability
PRESSPLANE
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Flexibility in Application
• Opens the door for new batt combinations
• Drying can be enhanced as a result through optimized pore distribution in the Z direction of the fabric
Sheetside
Rollside
Z Directional Pore Structure
Smaller Pores Larger Pores
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PRESSPLANE
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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.
©2019 Albany International Corp.
Advanced Technology
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BENEFITS
• Quick start-up
• Open over life
• Longer life potential due to resiliency and cleanability
• Excellent drying potential
• Improved moisture profileFEATURES
• Resilient, non-woven components
• Engineered dewatering
• Uniform pressure distribution
• Highly compressible fabric
• Absence of base fabric loom edges
SPRING M is a resilient non-woven technology. Developed for Tissue, this structure provides excellent nip-dewatering. The nip-dewatering flushes contaminants out of the press fabric structure and provides excellent post pressure roll consistencies.
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Cross Section of Spring M II
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Spring Non-Woven Compressibility Video
SPRING dts CD cut.wmv
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Caliper (mm) %Loss
New Used
AperTech Layer 0.523 0.489 7
Base Weave 1.549 1.191 23
After 4.2 Million Cycles
Spring M Resilience
• Spring Non-Woven base is built off of our AperTechtechnology platform
AperTech Base
Spring Non-Woven Base
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New Composite Technology – RPD-055
EXPECTED BENEFITS• Steady-State Pressing• Significantly improves press dryness• Open, conditioning responsive structure• Uniform pressure distribution
• Improved moisture profile• Enhanced dewatering• Less risk for wet streaks
FEATURES• A tissue batt structure• A reinforced and perforated composite
roll side• Improved fabric pressure uniformity• Excellent fabric stability• High nip dewatering with self cleaning
effect
RPD-055 is a new development product which employs a tissue batt structure with a reinforced and perforated composite layer underneath. The novel structure improves pressure uniformity and compaction resistance.
BacksidePaperside
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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.
©2019 Albany International Corp.
New Enhancement For All Products
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•Fibernetics 3D is a special surface batt fiber that is stronger and more heat tolerant than traditional fibers. It provides added resilience to stand up to the tough elements of a Tissue machine, helping improve wear properties and overall runnabilitythroughout the life of the fabric.
BENEFITS
• Stronger fiber improves wear resistance
• Increased thermal tolerance
• Reduced sheet moisture streaks
• Can be applied to any technology platform
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Grade: 14-25 gsm Tissue/Towel
Speed: 1500 mpm
Width: 3.7 m
CF with Suction Pressure Roll
POSITION Pickup
Technology Platform Fibernetics 3D
Weight, gsm - new 1290
Caliper, mm - new 2.61
Permeability, cfm - new 12
Days on 65
Reason for removal Scheduled
Comments Previous designs were
only running ~17 days
before getting into wear
streaks. Using the same
design and adding the
Fibernetics 3D got felt life
to 63+ days.**
Criterias for choice Improved wear
properties
Value to MillImproved Felt Life
and Runnability
CASE HISTORY – Dynavent II with Fibernetics 3D
**See Next Slide for Photos Comparing Before and After Adding Fibernetics 3D
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Standard Design (17 days) After Adding Fibernetics 3D (65 days)
CASE HISTORY – Dynavent II with Fibernetics 3D
Used Paper Side Surface of Fabric Used Paper Side Surface of Fabric
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Region Machine Position Style Former Press Speed (FPM) Speed (MPM) Grade Wet/Dry Crepe
SA 1 Pickup Dynavent II CF SF/SPR 5250 1600 Tissue Dry
SA 1 Pickup Dynavent II CF SF/SPR 4920 1500 Tissue/Towel Dry
SA 3 Pickup Hydroduct 200 CF SF/SPR 5315 1620 Tissue Dry
SA 2 Pickup Dynavent II CF SF/SPR 5085 1550 Tissue Dry
SA 1 Pickup Dynatex II CF SF/SPR 3600 1100 Tissue Dry
SA 2 Pickup Dynavent II CF SF/SPR 5085 1550 Tissue Dry
US 2 Pickup Dynavent II TW SF/SPR 4600 1400 Tissue Dry
CA 5 Pickup Dynavent II SBR SF/SPR 4600 1400 Tissue Dry
SA 4 Pickup Dynavent II CF SF/Shoe 4600 1400 Tissue Dry
SA 1 Pickup Dynatex II CF SF/SPR 3450 1050 Tissue Dry
Listed below are mills where Albany International has provided excellent performance with FIBERNETICS 3D
References
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AIC PROPRIETARY & CONFIDENTIAL
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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.
©2019 Albany International Corp.
Shoe Press Application Update
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Why The Growth of Shoe Presses in Tissue?
Nip length (mm) = 65-150mm
Nip
pre
ssure
(M
Pa)
Suction roll3.2 MPa peak
Shoe press1.5 MPa peak
90 kN/m
• A key factor in tissue production is bulk
• Increasing nip length lowers the peak pressure increasing bulk
• Dwell time is also increased to maintain dryness
• It is also possible to increase dryness to save energy
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Press Fabrics on a Shoe Press Machine
• Albany’s experience on shoe press Pickup applications has continued to grow exponentially as more machines have been installed
• Press Fabric design is critical for optimal machine performance
• Dewatering at the Suction Turning Roll is necessary
• Understanding the nip dynamics of a shoe press is needed to properly dewater the paper sheet
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Albany Focus on PU Shoe Applications
• As Tissue machines began installing more shoe presses throughout the Americas, our main goal was understanding how these Pickup fabrics needed to behave for a given application
• Albany’s Dynavent II has proven to be an industry leader on Tissue shoe press Pickup positions
• Dynavent II is run on more than 50% of all shoe presses in the Americas
• Engineered for these specific shoe press applications
• 4 more positions with trials made
• Other designs like Dynatex II and Pressplane 2 have also proven successful
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Albany Shoe Press Experience - Americas
• The percentage of shoe press Pickup positions Albany International has activity on in the Americas
• Where we already have existing business, or a recent trial was made ready to be installed on a position we currently do not supply
• The percentage of shoe press Pickup positions in the Americas exclusively running Albany Press Fabrics
• The percentage of shoe press Pickup positions in the Americas where Albany has at least half of the business
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AIC PROPRIETARY & CONFIDENTIAL
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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.
©2019 Albany International Corp.
Albany Press Fabric Plant Overview and Wrap-up
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Press Fabric Manufacturing Plants - Americas
1. Cowansville, Quebec, Canada
2. St. Stephen, South Carolina, U.S.A.
3. Indaial, State of Santa Catarina, Brazil
1
2
3
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Continuous Improvement Culture
Our manufacturing facilities have fully embraced the continuous improvement culture
• Visual Factory
• Job Methods/JIBs
• 5S
• TPM
• Kanban
• Value Stream Mapping
• PP/PPk
• Control Charts
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It’s all about...
SEAMTECH PLUS, SEAMPLANE, SEAM PRESSPLANE, PRESSPLANE, FIBERNETICS 3D, SPRING M, APERTECH, DYNAVENT, and DYNATEX are tradenames of Albany International Corp.