Published November 3, 2011 Gap Former Initial Dewatering Layout

Effect of Initial Dewatering Layout of a Gap

Former on Sheet Structure and Printability
Executive Summary
The main focus of this paper was to study the impact of three different types of gap formers on formation
nature and further on the properties of printability. Two of the tested forming sections were roll and blade
type gap formers and the third one a novel shoe and blade type gap former. The three tested gap formers
differ from each other with regard to the way the initial dewatering takes place, i.e. initial dewatering
speed (gap pressure) and time delay between the initial dewatering and the loadable blade section
dewatering.

The hypothesis of this study is that the different initial forming layouts have a significant effect on the z-
directional consistency profile after initial dewatering. The altered consistency and yield stress profile in
the z-direction change the depth of the sheet internal layers, where shear force field can improve the
formation of the sheet. From the tested forming section concepts the shoe and blade former gave the
smoothest through look impression of the paper and that had a positive effect on paper printability.

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Introduction
It has been stated by many studies that evenness of paper structure is a basic requirement of good
printability. The typical sources for print unevenness (density, color and gloss) originate from paper
formation, but also from paper properties like surface topography, porosity and surface chemistry. Print
unevenness has in principle an unlimited range of wavelengths, of which certain wavelengths are visually
more significant than others. Kajanto [1] suggests that the most significant wavelength range is 0.3 mm to
70 mm for normal reading distance. Smaller wavelengths and particularly the size of the pores contribute
to the printability of halftones that is governed by the dot properties. Dot gain causes the halftone contrast
to decrease. The typical dot related halftone print properties are missing dots, raggedness of the dot edge,
edge noise and the lack of sharpness. The influence of porosity is related to the random positioning of
pores at the surface. Other printability factors which affect the printability of halftones are surface
topography and light diffusion properties.

Formation can be influenced in many different ways. The typical wet end operations to adjust the
formation are furnish treatment as well as headbox and forming section adjustments. The effects of the
mechanical differences at the formation zone with different layouts and consistencies at the initial and
secondary dewatering (blade assisted) stages are discussed in this paper. The objective of this study is to
compare the newsprint papers produced
with three different gap forming concepts.
The main focus is on the phenomena that
control the formation nature and paper
printability.

Materials and Methods

Pilot Paper Machine
The three different forming section layouts
were examined on the pilot paper machine
located at the Valmet Paper Technology
Center in Jyväskylä, Finland. The tested
Figure 1. The tested forming section layouts
former types are presented in Figure 1.
Formers A and B represent roll and blade
type gap formers and C is a shoe and blade gap former. The most important process dimensions of the
pilot machine layout corresponded to a full scale production machine. The operating speed of the
machine was one of these dimensions.

The first forming section (A) was a roll and blade type former, which had a high wrap angle (35°) forming
roll. The forming roll dewatering was followed by a multifoil shoe, which was installed on the opposite
side from the forming roll and had three dewatering zones. A loading unit consisting of three individually
loaded loading elements was located on the same side as the forming roll. The loading elements were
positioned against the 2nd dewatering zone of the multifoil shoe.

The second forming section (B) was also a roll and blade type former, which had a low wrap angle (20°)
forming roll. The forming roll dewatering was followed by a blade dewatering unit. The loading elements

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were installed on the opposite side from the forming roll. The fixed side of the blade unit (opposite to the
loading side) consisted of two suction chambers, and the loading blades were positioned against the first
suction chamber, right after the forming roll dewatering.

The third forming section (C) was a shoe and blade type gap former equipped with loadable blades. The
forming shoe was followed by a blade dewatering unit. The loading element side of the blade unit
consisted of four loading elements. Similarly to former B, the fixed side of the blade unit consisted of two
suction chambers, and the loadable blades were located against the first suction chamber.

The produced paper grade was standard newsprint (45 g/m²) made of 100% Central European recycled
furnish (DIP). The freeness of the machine chest furnish was at the level of 120 to 130 ml, and paper
machine headbox freeness 60 to 70 ml. Fresh filler (clay) was added to the system in order to reach a 12 to
14% filler content target in the paper. A small amount (200 to 300 g/ton) of cationic polymer (C-PAM)
was added after the machine screen in order to keep
the first-pass retention at a stable target level (60 to Property Unit
65%). The running speed of the paper machine was Basis Weight 45 g/m2
1800 m/min at the forming section, which corresponds Filler content 12 - 14%
to 1880 m/min speed at the reel. The paper grade Tensile strength MD/CD ratio 3.5 - 4.0
targets are presented in Table 1. Retention level 60 - 65%
Table 1. Targets for the paper grade and process
On all of these former types, web forming and
dewatering is started under a constant pressure.
During the very first stages of constant pressure dewatering, there is still some turbulence from the
headbox slice jet, and shear forces are generated due to deceleration/acceleration of the jet velocity
corresponding to the fabric speed and dewatering pressure during the first dewatering element. At the
stage when fiber mats are formed on both surfaces, the partially formed web enters the blade forming area
and the pressure pulses generate shear forces and redistribute the fibers and fines.

On the novel type of shoe and blade gap former (C) the forming roll is replaced with a stationary shoe that
has a permeable surface structure and vacuum inside. The changeable radius offers good possibilities to
effectively influence the initial dewatering. It is even possible to alter the radius along the shoe length and
to create a different dewatering pressure at the early stages of the initial dewatering than at the later stages.

The main differences are related to the dewatering intensity and the proportions between the initial and
blade dewatering. Out of the three formers the time delay from the beginning of the initial dewatering to
the blade dewatering stage is the longest on former A. On former B the time delay is significantly shorter
compared to former A, and on former C the time delay is about the same as with B. The main difference
between former types B and C is the dewatering intensity at the initial dewatering stage.

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Basic Theory of Initial Roll or Shoe Dewatering

The dewatering pressure during the initial roll or shoe dewatering is basically governed by the following
equations:

where T is the fabric tension, R is the radius of the roll or shoe, p is the pressure in the vacuum chamber, σ
is the density of the stock suspension, h is the thickness of the stock layer, and v is the running speed. In
both tested roll and blade concepts the roll radius R was the same (0.8 m), and in the shoe and blade
concept the radius R of the shoe was significantly higher.

In roll and blade gap forming the separation point of the fabric from the forming roll surface has been
found to be very significant for dewatering mechanisms in many references [2, 3]. The measurements
made by Holm [3] revealed that vacuum generated at the separation point between the forming roll
surface and the forming fabric can be up to 20 to 30 kPa, while vacuum level during normal operation is
in the range of 0 to 15 kPa. There has been a proposal [4] to support the fabric on the roll side at the
separation point, and thus overcome the negative effect of the vacuum pulse on the web. However, such a
mechanical structure is not feasible on a full scale production machine. In pilot machine studies it has
been found that in this situation the pressure gradient keeps the fiber mat on the forming roll side in
proper contact with the fabric. The tension of the other fabric attempts to keep the fabric on a direct line
defined by the position of the dewatering elements and stock thickness. While the permeability of the
fabric is very high compared to the fiber mat, a very steep pressure gradient is formed at the connection
point of the fabric and fiber mat. This can cause the formed fiber mat to be detached from the fabric
surface. On the outward side relative to the forming roll, the stabilizing pressure gradient is missing and
high shear forces are generated. Under certain conditions these shear forces can exceed the yield stress of
the formed fiber mat and cause "crushing" type defects on the paper.

The mechanism is different when a forming shoe is used. It behaves in a similar manner to a foil, where
the pressure pulse at the trailing edge of the foil depends significantly only on the fabric angle on the
trailing side of the foil. In practical solutions where only a small angle at the trailing edge is used, the
pressure pulse can be considered to be insignificant. The shoe surface has been designed to minimize
deflection of the forming fabric between the support points, and thus it can be considered to be a non-
pulsating dewatering element.

Basic Phenomena of Blade Dewatering

The force acting on a fabric-web structure when it moves over a stationary blade depends mainly on fabric
deflection over the blade and fabric tension. Additional forces are created by possible vacuum acting
between the blades (causing fabric deflection) and loading forces of the loading elements, if they are
installed in the system. An exact analysis of the forces and the dewatering pressures during blade forming
are studied in many references [e.g. 5, 6], and are not discussed in detail in this paper.

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How the initial dewatering is performed and how it is divided between the initial and the following
dewatering phases is essential for the functionality of a gap former . In the following sections some of the
most important relationships between the fiber networks and shear forces acting on it are discussed.

Nordström and Norman [5] have proposed that the effect of the pressure pulses on the fiber network
equals a balance between improving and impairing mechanisms. Zhao and Kerekes [7] have formulated
this relationship:

where τy is the yield stress of the fiber suspension, τM is the yield stress of the formed mat, and dp/dx is the
applied shear stress. Kerekes et al. [7, 8] concluded that in order to improve paper formation after initial
dewatering with blade forces: a) shear forces should exceed the yield stress of the fiber flocs and fibers and
b) relative movement between the fibers should be high enough to create observable results. Dalpke and
Kerekes [9] studied the yield strength of the fiber mat network. Different types of fibers were found to
follow a relationship:

where a and b are coefficients and C is the consistency. They found out that longer fibers have a higher
value of a coefficient and coefficient b varies from 2.6 to 4. The dependency of pressure pulses on
consistency was postulated by Zhao and Kerekes in reference [7] and further analyzed by Kerekes et al. in
reference [8]. When the local consistency (considered as an average over web thickness) increases, it can
be concluded that: a) the height of undrained stock suspension between the formed fiber mats decreases
and b) permeability of the drained fiber mats decreases. These will lead to a situation where the blades
operated at the higher local consistency cause the pressure pulses to have a higher maximum amplitude.

Forming Section A Forming Section B Forming Section C

Property:
LB off LB on
2
Basis Weight (g/m ) 44.4 44.6 44.7
Filler content (%) 9 13.1 11
MD/CD ratio 3.5 3.6 3.4
2
Ambertec beta formation (g/m ) 3.6 3.6 2.6 2.1
Kajaani formation index ()* 59 57 66 79
Air permeance (ml/min)* 390 440 380 330
Headbox consistency 0.85%  0.97% 1.08%
Total retention 68%  70% 66%
2
Oil absorbency C-U 10 (g/m )
• FS 18.8 19.3 16.9 17.3
• BS 24.7 24.5 23.0 23.0
2
Internal strength (Huygen) (J/m ) 218 217 281 240
*) uncalendered base sheet
Table 2. Basic paper properties of the uncalendered samples

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In the commercial scale production of printing papers, various fillers and additives are used. Retention
aids, which typically are cationic long-chain polymers, are used to flocculate filler and fiber fines material
on the fiber surfaces. However, these polymers also tend to increase the strength of the fiber flocs and thus
the formation deteriorates. Swerin and Mähler found in their studies [10] with a pilot scale gap former,
that higher oriented shear was required with chemically flocculated suspension to achieve good
formation.

Results and Discussion

The basic paper properties were analyzed from the paper samples manufactured with the forming section
layouts A, B, and C (see Table 2 previous page). The weakest formation values were measured for sample
A. It was also established that in this case the loading elements were not able to improve formation – on
the contrary, visual formation deteriorated and air permeance increased with the applied loading
pressure. Sample C had simultaneously the best formation values (visual and mass variation) and low air
permeance.

The basis weight distribution in small scale was measured with a Beta-radiogram analysis method using a
Fuji BAS-1800 II Storage Phosphor Screen device. The radiation source is a flat C-14 beta-radiation
source, the dimensions of which are 150 mm x 200 mm x 1 mm. The transmitted radiation produces a

Figure 2. Beta-radiogram pictures of formation with the tested forming sections

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picture of the sample on a BAS IP-MS 2025 imaging plate, which is read and formation indices are
calculated. This method gives the actual mass variation in various wavelengths.

The basis weight maps of the paper samples are presented in Figure 2 on the previous page. Sample C has
the most even structure and sample A has the highest variability. In contrast to earlier observations
presented by Nordström and Norman [11], it was noticed that by altering the proportion of initial
dewatering, the total mass variation in the paper samples was reduced. Even though the same fiber
material was used in these trials, the mass
variation in the fiber scale was found to
be lowest with forming section C. It is
postulated here that the altered forming
mechanism distributes fine material
more evenly in-plane.

The layered formation was analyzed from

the samples produced with optimal
running conditions for each forming
section layout. Forming section C
produced the most even formation
throughout the z-direction of the sheet. Figure 3. Flocculation in z-directional paper layers
Layout A had the poorest formation in
practically all the paper layers. This was the case even though the lowest possible headbox consistency was
used. Headbox consistency was limited due to the crushing type defects in the sheet that originated at the
fabric separation point from the forming roll surface. The flocculation indices calculated from the
individual strips are presented in Figure 3.

Fiber orientation was also measured from

individual paper strips in the z-direction.
The results are presented in Figure 4.
Forming section C had a larger radius of
the dewatering shoe and thus the pressure
during the initial dewatering was lower.
However, the anisotropy of the sheet is
symmetric and very similar to that of
forming sections A and B. It can be
concluded that during the initial
dewatering the larger radius and thus the
lower dewatering speed allow the Figure 4. Sheet anisotropy in the z-direction
orientated shear originating from the
jet/speed-speed difference to break flocs and orientate fibers into deeper layers of the paper. In the case of
small radius (i.e. forming roll), the gap itself produces shear forces, but at the same time a high
perpendicular velocity (dewatering) reduces the orientation magnitude.

The balance between forming at the initial dewatering stage and forming at loadable blade dewatering
varies between the different concepts, the proportion of initial dewatering decreases from forming section

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A to C. The dewatering intensity, which is understood as dewatering pressure during initial dewatering, is
the lowest with layout C.

One explanation for the formation behavior in these experiments is that the steepness of the consistency
profile in z-direction of the web varies due to the dewatering differences between the tested forming
concepts. Figure 5 clarifies the postulated situation.

Figure 5. Postulated web consistency profile at loadable blade area with different forming concepts

It is assumed that the z-directional consistency profile gets steeper as: 1) initial dewatering speed increases
(high gap pressure), 2) drainage resistance of headbox stock decreases (lower headbox consistency), and
3) drainage resistance of forming fabrics decreases (more open fabrics).

Forming section A has the most effective initial dewatering prior to the loadable blades, and thus a lower
headbox consistency is needed to keep the average consistency at the operating area of the loadable blades.
However, this will lead to a situation where the consistency gradient between the already formed surface
layers and the middle layers of the web increases. It was established that even with the lowest headbox
consistency the loading elements were not able to improve formation, but on the contrary, visual
formation impaired and air permeance of the sheet increased. It is suggested here that the yield stress of
the flocs themselves has not been exceeded, but the flocs can move slightly relative to each other, thus
creating a bigger void between them and air passages through the sheet.

In forming section B the proportion of initial dewatering is smaller. Due to this fact a higher headbox
consistency can be used, increasing the drainage resistance in the very beginning of dewatering. An
appropriate yield stress area of the fiber network can be reached with a higher headbox consistency
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(pumping energy savings), and the blade section can still efficiently improve the formation. It was also
noted that air permeance of the sheet remained at a low level. It is postulated here that fibers detached
from individual flocs can now fill the void between the flocs (shear assisted self-healing).

In forming section C the intensity of initial dewatering is the smallest. The higher radius of the shoe leads
to lower dewatering pressure, and due to the capacity dimensioning of the shoe, a high headbox
consistency can be used. This leads to a situation where: a) the orientated shear is not dampened too fast
and is utilized to improve surface formation during the first dewatering phase, and b) a low consistency
gradient between the surfaces and the middle layers is formed. Additionally, the gentle release of the
fabrics from the shoe surface allows using low average consistency without the risk of crushing type sheet
defects. As shown in the previously presented formation measurements, the benefits in paper structure
can be seen in the z-directional structure. When the loading blades are applied in an appropriate
consistency profile, the induced shear forces can redistribute fibers and fines material throughout the
sheet, and thus the pore structure of the sheet is not negatively affected. This was seen as low air
permeance and oil absorbency values. These findings are consistent with the theory of formation
improvement presented in the references.

Printability of Different Paper Structures

In order to study the effect of base paper structure on printability, the papers produced with full scale
production paper machines equipped with forming concepts B and C were printed on a commercial scale
print press. The print press was a Heidelberg Web-8 with 4-color coldset printing. The paper samples
were printed to constant density targets.

Former B Former C
2
Ambertec beta formation (g/m ) 2.6 1.9
Kajaani formation index () 69 85
Air permeance (ml/min) 186 300
2
Cobb-Unger10 (g/m )
• FS 12.8 16.0
• BS 18.4 17.2
Table 3. Paper properties of production machine samples

Figure 6. Production machine samples with forming sections B (left) and C (right).

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The paper properties of the non-printed

samples were measured at the Valmet
Jyväskylä Paper Technology Center. It was
detected that the properties corresponded
very well to the measurements made from
the pilot machine samples produced with
similar concepts.

Beta-radiograms were also measured and

they gave very similar results to those
previously presented in Figure 2. The
production machine samples are presented Figure 7. Variance of the basis weight measured from production
in Figure 6 (previous page). The basis machine samples
weight variations in different wavelengths
are presented in Figure 7. These results
confirm the previous findings where the
smooth formation was reached with low-
intensity initial dewatering combined with a
blade dewatering unit.

Mottling of the printed samples was

evaluated with Papeye software. The
mottling measurements were made from
areas printed with 100% cyan. The results
show that forming concept C produced the
Figure 8. Papeye mottling measured from printed (C100%)
lowest mottling values (lower values
production machine samples
indicate visually more even color coverage).
The measured values are presented in Figure 8.Visual evaluation of the samples confirmed the same
result. The number of printed samples was 30,000 copies and the samples were taken at the beginning and
at the end. Mottling remained at the same level, which indicates that there is no significant build-up on
the printing plates and no difference between concepts B and C.

The show-through of the papers was evaluated visually. Pictures of 240% black areas printed on both sides
of paper are presented in Figure 9. The formation of the paper influences show-through in such a way

Figure 9. Show-through of the papers manufactured with forming sections B (right) and C (left)

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that the unevenness of the show-through increases with poorer formation. This can be directly explained
with flocculation, where higher basis weight positions have opacity and thus lower show-through. With
respect to evenness of the show-through, a visually more uniform formation can be considered beneficial.

Conclusions
The printability of paper was found to be the best with the new shoe and blade (former C) forming
section. The improved quality was also found in the layered paper structure, formation on individual
layers was more even. It was postulated that the layout of the initial dewatering determines the z-
directional consistency profile of the paper prior to entering the pulsating dewatering stage. It can be
concluded that in former C the z-directional yield stress profile of the paper is well balanced with the
shear forces applied during the different stages of dewatering. In the pilot trial it was also established that
with former type A, a negative impact on paper properties was created when shear forces were applied.

References
1. Kajanto I.,Effect of Formation on Print Unevenness with Uncoated Woodfree Papers, Doctoral thesis,
Helsinki University of Technology, Espoo, Finland 1991.
2. Erkkilä A-L, Pakarinen P, Odell M, The Effect of Forming Mechanisms on Layered Fiber Structure in Roll
and Blade Gap Forming. TAPPI 1999 Papermakers Conference, TAPPI Press. Atlanta 1999. pp. 389-400.
3. Holm R., Fluid mechanics of fibre suspension related to papermaking, Doctoral Thesis, KTH 2005.
4. Pat. EP1853760. Dewatering Apparatus, (Norman, B., Hermansson, L.). App. EP20060716944, 2006-2-27.
Publ. 2007-11-14.
5. Nordström B., Norman B., Effects of headbox jet quality and blade pulse force on formation, retention and
mechanical properties during roll-blade forming with curved blades. Nord. Pulp Pap. Res. J.. 10(1995):1.
pp. 33-45.
6. Zahrai S., Bark F.H., Norman B., An Analysis of Blade Dewatering in a Twin-Wire Paper Machine, JPPS
23(1997):9. pp. 452-459.
7. Zhao R.H., Kerekes R.J., The effect of consistency on pressure pulses in blade gap formers, Pap. Puu.
(78)1996:1-2. pp. 36-38.
8. Kerekes R.J., Dalpke B., Jong J.H., The Hydrodynamics of Formation Improvement by Blades in Twin-Wire
Formers. JPPS 33(2007):4. pp. 183-188.
9. Dalpke B., Kerekes R.J.,The Influence of Fibre Properties on the Apparent Yield Stress of Flocculated Pulp
Suspensions, JPPS 31(2005):1. pp.39-43.
10. Swerin A., Mähler A., Formation, retention and drainage of a fine paper stock during twin-wire roll-blade
forming. Implications of fibre network strength. Nord Pulp Pap. Res. J. 11(1996):1. pp. 36-42.
11. Nordström B., Norman B., Effects of Paper Properties and Retention of the Proportion of Roll Dewatering
During Twin-Wire Roll-Blade Forming of TMP, JPPS 22(1996):8. pp. 283-289.

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