aic proprietary & confidential matt bryer - albany · aic proprietary & confidential 1 matt...

AIC PROPRIETARY & CONFIDENTIAL

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.

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.

Matt Bryer, Product Manager - Tissue Press - Americas

New Press Fabric Technology and Application

Discussion Topics

New Press Fabric Technology for the Americas (North America + South America) Seamed

Endless

Advanced

New Enhancement

Shoe Press Application Updates

Update on Seamed Technology

Drivers for Albany Seamed Press Fabric Growth

Secondary Benefits Included Faster Installation and Less Manpower Needed During Installation

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

Albany Seamed Press Fabrics By The Numbers….2011 – H1 2019

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

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

Albany Seamed Fabric Evolution

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.

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

Improved Pressure Gradient

Uhle Box Cover Design - Seams

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.

Cross Section of PressPlane 2

Benefits of PressPlane Base Structure

More open structure for: • Better drainage

• Easy to clean

Base Permeability

PRESSPLANE

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

PRESSPLANE

Advanced Technology

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.

Cross Section of Spring M II

Spring Non-Woven Compressibility Video

SPRING dts CD cut.wmv

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

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

New Enhancement For All Products

•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

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

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

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 1 Pickup Dynatex II CF SF/SPR 3600 1100 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

Shoe Press Application Update

Why The Growth of Shoe Presses in Tissue?

Nip length (mm) = 65-150mm

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

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

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

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

Albany Press Fabric Plant Overview and Wrap-up

Press Fabric Manufacturing Plants - Americas

1. Cowansville, Quebec, Canada

2. St. Stephen, South Carolina, U.S.A.

3. Indaial, State of Santa Catarina, Brazil

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

It’s all about...

SEAMTECH PLUS, SEAMPLANE, SEAM PRESSPLANE, PRESSPLANE, FIBERNETICS 3D, SPRING M, APERTECH, DYNAVENT, and DYNATEX are tradenames of Albany International Corp.

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