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TTL FRS 2010 | 2010-03-28 | 1
TAPPI
New Fabric Technology
Tom E. CoulterVP Product ManagementVoith Paper Fabric & Roll Systems

TTL FRS 2010, 2010-03-28
Agenda
New Technology Development
Next Generation Triple Layer Forming Fabric
Next Generation Hybrid Technology Press Fabric

Papermaking Challenges Drive R&D Efforts
Health & Safety Energy Sheet Quality Production Environment

Global Product Development and Applied Research
Product Development Groups
Forming Press Drying
Research Technology Platforms
Material
Surface
Simulation
Textile/NW
Analytic
Fabrics & Rolls
Technology Scale up and Transfer
FIN

New technology tested at our Paper Technology Center

Next Generation Triple LayerDesigned to meet the full range of customer demands
A unique balance
Sheet Quality
Industry high Fiber Support Fines Retention Formation Cleaner runnability
Industry high Open Area headbox flows / formation
Performance
Industry high Wear Volume Life Potential
Thin Caliper (down to 0.026) Couch Solids Cleaner runnability

IS
Comparison of Features Next Generation vs Conventional Triple Layer
0
50
100
150
200
250
0 75 100 125 150 175 200 225 250
ARI (Wear Volume value)
FS
I
Medium Mesh TL0.13 / 0.21mm
warpsets
Fine Mesh TL0.11 / 0.18mm warpsetsNext Generation

Next Generation - Results
Machine Data Results / Benefits Exceptional fabric stability
most stable design we have ever run on Backing Position
Increased Drainage Sheet Formation improved with higher headbox flows
Industry high Wear Volume Competition triple layer averaged 42 days Next Generation has run 87 days
Ran cleaner than other designs
330 (8.50 m)Width
4100 fpm (1250 m/min)Speed
BelBaie Former
Pulp Furnish
Woodfree-CoatedGrade
Run
ning
Tim
e [g
ays]
Next Generation TL
Standard TL

Mill Cost Benefits by Increased Backing Position Fa bric Life
BelBaie WoodFree Coated
0
100.000
200.000
300.000
400.000
500.000
600.000
700.000
800.000
900.000
Fabric PurchaseCosts
Downtime Costs toChange Fabric
Total Cost ofOpperation
StanardNext Generation
Annual Costs of Operating
Backing Fabrics on PM7 Backing
Fabric cost savings = $ 250,000
Down time savings = $ 120,000
Total Annual Savings = $ 370,000
Val
ue[U
S $
]

Machine Data Results / Benefits
290 (7.30m) Width3805 fpm (1160 m/min)SpeedDuoFormer DFormerNewsprintGrade Significant increase in fabric wear potential
TL competition averaging under 50 days Next Generation has run over 100 days
Increased mechanical retention reduced Retention Aide usage / improved Formation Reduced drive loads
Improved MD stablity limited Stretch Roll capacity
Run
ning
Tim
e [g
ays]
Next Generation
Standard

Lower power consumptionAdditional benefits
Cost comparison Competitor Voith
Fabric cost ($) $80 000 $84 000
Life time (days) 40 80
Fabric changes / year 9 5
Cost savings 300 000
Fabric costs ($/year) $720 000 $420 000
Additional benefits Reduced retention aid usage
DuoFormer D Newsprint
Mill Cost Benefits by Increased Base Position Fabri c Life

330 (8.40 m) Width4100 fpm (1250 m/min)SpeedFourdrinierFormerLWCGrade
Increased headbox flows compared to competition products
cleaner HB operation / reduced wet end breaks Improved Formation
Eliminated Stock-On Stock-Off guiding issues Improved Trim quality Improved sheet 2-sigma profile Excellent wear potential / excellent stability Improved Couch Solids by 0.5 1.0%

Formation ImprovementAmbertec Formation (Standard Deviation lower valu es = better formation)
Fourdrinier LWC
0,59
0,57 0,57
0,54
0,59
0,62
Front Side Middle Drive Side
For
mat
ion
norm
aliz
ed (
g/
m)
With PF ISW 2008-04-24 60g/m
With competition 2008-06-26 60g/m
0,640
0,630 0,600
0,600
0,660
0,670
For
mat
ion
norm
aliz
ed (
g/
m)
For
mat
ion
norm
aliz
ed (
g/
m)
-04- -04-
-06- - -Competition TLNext Generation TL

IS
Next Generation Series of Products
0
50
100
150
200
250
0 50 100 150 200 250 300 350 400
ARI (Wear Volume Value)
FS
I
Next Generation
GraphicsNext Generation
Graphics / B&PNext Generation
B&P

Press Fabric Innovation Hybrid Technology
Non-woven, elastomeric roll side structure.
Elastomeric Yarn provides resiliency for vibration dampening and steady state pressing throughout felt life.
Compressibility provides a quick startup and increased nip dewatering if applicable.
MD rollside Flow Channels provide low MD flow resistance and increased dewatering rates.

Water Load to Reach SaturationFelt Inlet MR=0.25
Late Life
-400
-200
0
200
400
600
125 175 225 275 375
Press Load (pli)
Wat
er lo
ad (g
sm)
Triple Layer 1
Triple Layer 2
3 Layer HT
Water Load to Reach SaturationFelt Inlet MR=0.25
Early Life
-400
-200
0
200
400
600
125 175 225 275 375
Press Load (pli)
Wat
er lo
ad (g
sm)
Triple Layer 1
Triple Layer 2
Triple Layer HT
Resiliency Void Volume Differential between High and Low Loadi ngs
1.6
1.8
2.0
2.2
2.4
2.6
Triple Layer 1 Triple Layer HT Triple Layer 2
Voi
d V
olum
e (c
m3 /
ft2 )
15000 Cycles
115000 Cycles
380000 Cycles
Early Life
Late Life
Rate of Caliper Loss@ 225 pli
10
16
22
28
34
40
Triple Layer 1 Triple Layer HT Triple Layer 2
.001
" / m
illion
cyc
les
Press Fabric Innovation Hybrid Technology

220 (5.6m) Width1000 fpm (300 m/min)SpeedOpen Draw 2ndPressCoated Bleached BoardGrade Basis weight reduction on 8-12 pt. grades
1.35% weight reduction, equates to 154 tons/month
Customer verified $526,300 savings per year
G
W
G
W
HB HB
Basis Weight
Savings
Hybrid Technology Seamed Press Fabric Results

278 (7m) Width3000 fpm (909 m/min)SpeedTri-Np BtmPressUncoated FreeGrade Fabrics run smooth early in life.
Vibration increases after two weeks as the fabric compacts and fills.
HT fabric ran 32 days scheduled off with no increase in vibration noted through run
HB HBHBHB
HBHB
G
PM63 - 1ST PRESS TEND SIDE1ST PR.TD -P3A #2 ROLL 1ST PRESS-PRESS ROLL AX
Route Spectrum 10-Nov-08 11:54:40
OVERALL= .0861 V-DG PK = .0858 AMPS. = 100.0 FPM = 2587. (6.11 Hz)
0 50 100 150 200 250 300 350 400
0
0.02
0.04
0.06
0.08
0.10
Frequency in Hz
PK
Vel
ocity
in In
/Sec
>SKF 23152CA FTF: 2.67 BSF: 23.36 BPFO: 53.32 BPFI: 68.79 >SKF 23152C FTF: 2.67 BSF: 23.64 BPFO: 56.13 BPFI: 72.09 >TOR 23152 FTF: 2.68 BSF: 24.27 BPFO: 56.30 BPFI: 71.92 >FAG 23152 FTF: 2.69 BSF: 24.73
PM63 - 1ST PRESS TEND SIDE1ST PR.TD -P3A #2 ROLL 1ST PRESS-PRESS ROLL AX
0 50 100 150 200 250 300 350 400
0
0.02
0.04
0.06
0.08
0.10
Frequency in Hz
PK
Vel
ocity
in In
/Sec

278 (7m) Width3000 fpm (909 m/min)SpeedTri-Np BtmPressUncoated FreeGrade Fabrics run smooth early in life.
Vibration increases after two weeks as the fabric compacts and fills.
Improved CD moisture profile variation by 40%
HB HBHBHB
HBHB
G

234 (5.9m) Width1300 fpm (394 m/min)SpeedDBL Felted 1st & 2ndPressCoated LinerGrade
Increased press exit solids 1.5- 2%
5.2% TPH increase on average
Improved speeds all grades
Lower uhle box vacuums over life
3% reduction in basis weight on average
No. 6 Press Solids vs. Press Fabric Style
40.00% 42.00% 44.00% 46.00% 48.00% 50.00% 52.00% 54.00%
Avg
93 lb
105 lb
Bas
is W
t.
% Press Solids
VOITH HT 1st Press Other 1st Press VOITH HT 2nd Press Others 2nd Press

Optimum bridging effect
Lower fl

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