Wet End Forming Equipment Rebuilds on Containerboard Machines for Cost Savings

Dean Miller, Claes Holmqvist, Ken Stager, Vaughn Wildfong, Jay Shands
Paperchine -JohnsonFoils, Springfield, MA

ABSTRACT

Through fourdrinier table drainage equipment and top former upgrades, there are often opportunities for significant
cost reductions through quality improvements and reduced energy usage on containerboard grades. Challenges that
many machines face include decreasing furnish quality, increasing speeds, running wide grade ranges, and trends to
lighter weights. Table configurations have evolved with adjustable features to provide flexibility to better handle the
wide range of grade conditions typically seen on many machines. Top formers have also evolved with engineered
geometries to handle higher flow capacities, improve formation, and provide strength enhancements. In this paper,
typical rebuild opportunities for improvements on containerboard grades are discussed and case studies illustrating
the implementation of these considerations are presented.

INTRODUCTION

To maintain profitability, containerboard producers are continually looking to keep costs as low as possible while
meeting quality targets and running high production rates. Challenges that many containerboard machines face
include decreasing furnish quality, increasing speeds, and market conditions forcing trends to lighter weights.
Further, on any one machine a wide range of weights and speeds are typically run putting additional challenges on
the papermaker.

Table configurations have evolved with adjustable features to provide better flexibility to better handle the wide
range of grade conditions typically seen on many machines. Top formers have also evolved with engineered
geometries to handle higher flow capacities, improve formation, and provide strength enhancements. On
containerboard grades, strength improvements offer the opportunity of cost savings typically through running lower
basis weight, lower chemical strength additive rates, lower refining energy usage, and/or increases in production
rates. In this paper, typical rebuild opportunities for improvements on containerboard grades are discussed and case
studies illustrating the implementation of these considerations are presented.

FOURDRINIER TABLE – SHEAR CONTROL

In order to improve the sheet structure and optimize the critical properties during single-wire forming, what is called
‘stock activity’ is generated during the drainage process. Various table elements, foil blades being the most common
example, are used to locally deflect the fabric downwards as it travels along the machine. The undulating fabric path
results in vertical accelerations of the stock that create internal flows in the suspension layer. To the eye these are
seen as disturbances on the surface in the form of small bumps or spouts. However, what is relevant to papermaking
is the corresponding internal shearing and stretching of the suspension.

If of correct magnitude, the strains induced in the suspension can randomize the fiber distribution and increase the
degree of cross-machine alignment of the fibers, flocs can be disrupted, and sheet self-healing effects be enhanced
through increased fiber material mobility. If the internal flows are excessive, the web being formed on the wire will
get damaged, with subsequent loss of sheet quality.

Drainage elements deflect the fabric through self generated vacuum forces or by externally applied vacuums. For
foils, the drainage forces are self generated and will strongly depend on speed. So wire deflection and shear will

PaperCon 2012 Page 1802

depend on speed [1, 2] making it impossible to have optimal shear conditions for each grade when running a wide
range of speeds. Foils and foil-like drainage devices have evolved to have adjustable angles on the run to provide
more flexibility in controlling shear.

Another commonly used tool for generating shear is to use a blade that generates agitation by first having a land area
and a diverging angle similar to a standard foil, followed by a converging angle back to the fabric level (Fig. 1 ).

Fig. 1. Positive pressure agitation blade.

The combination of the fabric deflection and stock re-entry has proven to be a very effective tool for generating
shear and has become popular on slower speed heavier weight grades that can benefit from increased shear.
However, a blade designed to be effective at lower speeds, often may generate excessive shear and hurt strength
properties and retention for lighter weight, higher speed grades.

This has led to the development of foil units where these types of blades can either be raised and engaged or lowered
and dis-engaged depending on the grade and speed being run. Typically, these are spaced alternating with support
blades whose top faces are at table level. Additional deflection control can be provided by using foil angle
adjustable blades in the support positions as illustrated in Fig. 2. These types of units are becoming increasingly
popular as they provide the papermaker with the flexibility for controlling shear over a wide range of speeds.

Fig. 2. Gravity foil unit with adjustable angle support blades and intermediate positive pressure agitation blades.

For vacuum assisted elements, a widely used method to control fabric deflection and shear has been to use the
“broken plane” blade set-up on vacuum boxes. In these set-ups, there are support blades at the table level with
intermediate control blades with their top faces below the table level. Vacuum will pull the fabrics down to these
blades and also into the slots between the blades, leading to deflections that drive stock activity as illustrated in Fig.
3. The centrifugal forces that are generated, which are proportional to the square of the speed, U, and inversely
proportional to the radius of deflection, R, drive the spout growth [3].

R(xMD)
U

Fig. 3. Fabric deflection and stock excitation in a “broken plane” pulsative drainage device.

PaperCon 2012 Page 1803

Using a positive pressure agitation blade in the intermediate control position will provide additional shear. The
control blades are vertical adjustable allowing deflection and shear control (Fig. 4.)

Support Control
Blades Blades

VACUUM VACUUM VACUUM

Control Blades Vertically Adjustable

Fig. 4. Vacuum assisted pulsative control device with vertically adjustable control blades.

These devices are either adjusted manually or can be controlled through an actuator. A typical set-up with a positive
pressure agitation style control blade is shown in Fig. 5.

Fig. 5. Vacuum assisted pulsative control device with vertically adjustable positive pressure agitation blades.

FOURDRINIER TABLE - OTHER CONSIDERATIONS

Low Vacuum Section

Lowering headbox consistency is often an avenue for improving formation and strength properties. Increasing
production rates also requires additional capacity to maintain headbox consistencies.

For the fourdrinier table, table capacity will need to be evaluated for handling increased capacity. Potential
bottlenecks may include unit flooding due to insufficient drop leg size for the target vacuums or limitations due to
outlet design. Remedies include modifying or replacing units with limitations and/or adding new units for
additional capacity.

High Vacuum Section

The high vacuum section contributes significantly to the total fourdrinier drag load. Improvements here not only
can lead to improved dryness and efficiency, but also to significant cost savings through reduced energy usage.

Many machines still use a series of single compartment suction boxes in this section. Improved dryness and reduced
drive loads may often be achieved through using multiple zone vacuum boxes. As illustrated in Fig. 6, these make
more efficient use of available air flow by not allowing the vacuum to drop to atmospheric conditions between
zones. These are also designed to avoid blade lubrication issues for lower drag.

PaperCon 2012 Page 1804

 17% 19%
15% 10” 17% 10”
14% P 14% P
5”
5”
In Hg
In Hg

Three Single Hivacs Trivac

Fig. 6. Multiple zone vacuum box concept.

A high vacuum box designed for couch level vacuums and high air flow can be used to replace a rotary vacuum
couch. A static unit will have lower vacuum requirements, provide comparable or higher dryness, and avoids
potential rewet issues. These units can be used in addition to the multiple zone high vacuum box or incorporated
into their designs.

FOURDRINIER TABLE – CASE STUDIES

Two case studies are reported here, one producing medium with 100% OCC and the other producing 2-ply
linerboard with a primarily virgin pine furnish.

Case Study 1

The first case study considered is a corrugated medium machine that was looking to improve both quality and
production rates. A main challenge was the slow draining nature of the stock. Basic operating conditions for this
machine are shown in Fig. 7.

Product: Corrugating Medium

Basis weight: 90 to 200 gsm
Machine speed: 400 to 640 mpm
Furnish: 100% OCC
Headbox Consistency: 0.7% to 0.9%
Retention: 70% to 85%
Freeness: 65 to 70 SR

Fig. 7. Operating conditions for case study 1.

The pre-rebuild fourdrinier table, shown in Fig. 8, was primarily a standard foil table with a number of low vacuum
boxes and a series of single zone high vacuum boxes.

Single Compartment
Low Vac Boxes Foil Units
Hi Vac Boxes

Fig. 8. Pre-rebuild table layout.

This table was rebuilt in phases. The first phase included adding capacity in the low vacuum section and then as a
second phase, replacing the (6) single zone high vacuum boxes with a single (4) zone high vacuum box (Fig. 9).

PaperCon 2012 Page 1805

 New New
New Pulsative
(4) Compartment (2) Compartment
Drainage Unit
Hi Vac Box Low Vac Box

Fig. 9. Table after initial modifications for capacity increases.

Operating speed was able to be increased by 90 mpm and the high vacuum section work resulted in a 1.5% increase
in pre-couch dryness, while lowering drag loads by 31%.

For the third phase, the focus was on strength improvement and some further capacity increases.
For this phase, the old forming board was replaced with a new one and the foil table was replaced with a series of
control fabric deflection vacuum assisted drainage elements.

New Pulsative Drainage Unit

with Adjustable Control Blades

New Forming
New New Pulsative Drainage Units Board
DuoFlo

New Ceramics for vacuum control

existing units valves

Fig. 10. Phase III of table rebuild, case study 1.

The first unit after the forming board was supplied with vertically adjustable positive pressure agitation style control
style blades to provide flexibility for activity and shear control.

The photographs of stock surface activity in Fig. 11 show the change in surface activity for a 170 gsm grade at 420
mpm due to a change in position of the adjustable blades. In the photograph on the left, the agitation style blades
were placed up at table level, while on the right it was lowered, but still being in contact with the fabric. One can
see that lowering the control blades are a tool for increasing stock activity/shear. The condition on the right led to
improvements in formation and strength.

Fig. 11. Effect of vertical adjustable of control blade on stock activity for a 170 gsm grade at 420 mpm for all other
conditions similar. The blades were raised to table level on left and in a lowered position, but fabric contacting
position, on the right.

PaperCon 2012 Page 1806

With the new set-up and running at slightly lower headbox consistency, formation was improved significantly as
seen in Fig. 12.

(a) (b)

Fig. 12. Formation before (a) and after (b) the rebuild for a 170 gsm sheet.

The formation and strength improvements were attributed in part to running lower headbox consistency and
improving table shear conditions and likely due to both fiber re-alignment as well as the better formation. The
portion of the effect of the adjustable shear on the table allowed some further optimization, increasing strength
values as shown in Table I below.

Table I. Strength changes from control blade adjustment.

Property Strength Gain

Flat Crush of Corrugating Medium, CMT test 8%
MD Short Span Compression test 4%
CD Short Span Compression test 15%

Cost savings were realized through being able to run 30% less applied starch at the size press. As a result, steam
consumption was also reduced in the after size press drying.

Case Study 2

The second case study reported here is for a 2-ply linerboard machine running with a high percentage of virgin pine
(~65%). The main grade was a 56 lb/1000 ft2 (270 gsm) sheet.

Fig. 13. Operating Conditions.

The primary objectives were to increase base table capacity giving flexibility to run slower draining furnishes and to
improve formation and strength. Pre-rebuild and post-rebuild table configurations are illustrated in Fig. 14.

PaperCon 2012 Page 1807

 Before Rebuild

After Rebuild
New Pulsative Drainage Units
with Adjustable Control Blades
New
(2) Zone
Lo Vac Box Dropleg modifications

Fig. 14. Fourdriner table before and after rebuild.

For this rebuild, early drainage elements were replaced with (2) drainage units with vertically adjustable positive
pressure agitation style control blades. A (2) zone low vacuum boxes was added before the secondary headbox for
additional drainage capacity. Drop legs were also modified for increased capacity. The vacuum control system was
also upgraded.

For the 56 lb/1000 ft2 (274 gsm) high performance grade, improvements in formation and strength were achieved.
Optimization trials showed that potential cost savings could be achieved through several different avenues. When
refining was held to pre-rebuild levels, basis weight was able to be lowered 1% and speed increased by 10%.

When basis weight was held to pre-rebuild conditions, refining was reduced 16% with an average speed increase of
7% relative to year- to-date values. Ambertec formation improved by 9%.

For the 69 lb/1000 ft2 (337 gsm) burst (Mullen) grade, good strength values and lowest steam consumption in the
dryers were found at control blade positions set for high activity levels.

Refining energy was able to be reduced by 38% and speed was increased by 7%.

TOP FORMERS

There are many types of board machine forming configurations that utilize top formers.

Fig. 15. Example of a two-ply board machine with top formers.

In twin wire forming conditions, pressure pulses and shear are generated as the fabric/suspension sandwich deflects
over elements [4]. The level of these pulses and resulting shear has a strong impact on sheet properties. Some shear

PaperCon 2012 Page 1808

is desirable for improved formation, but too much shear can easily lead to loss of strength properties and crushing.
These problems tend to worsen with slower draining furnishes that do not allow the pressures to be relieved.

Often conditions are found where too high pressure pulses are occurring in the top former and the machine operators
are forced to dry up the sheet into the top former to avoid crushing and its harmful effects on sheet properties [5].

To eliminate crushing, top former geometry can be modified to lower pressure pulses, of which an example is shown
as Fig. 16. In this example, pressures were lowered by about 50%. This allows one to run lower consistencies into
the top former, leading to formation and strength enhancements for such properties as burst.

Fig 16. Comparison of pre (red) and post (blue) rebuild lead-in box pressure fields for a top former lead-in box.
Pressures are listed as percent of maximum pre-rebuild pressure.

TOP FORMERS – CASE STUDY

This case study is for a 2-ply linerboard machine running 100% OCC where the top ply was added with a secondary
headbox and drained with a blade style top former. Basic operating conditions are shown in Fig. 17.

Fig. 17. Operating Conditions.

Before the rebuild (Fig. 17), the headbox jet was landing on a flat landing box and then trapped over a small lead-in
box that was generating high intensity pressure pulses. Headbox flow was being severely limited due to crushing.
The primary suspect for the crushing was high intensity curved lead-in box over which the initial upwards drainage
occurred.

Fig. 17. Pre-rebuild top former configuration.

PaperCon 2012 Page 1809

As shown in Fig. 18. The landing box was replaced with a “curved” design that allowed jet impingement at lower
angles; the lead-in box was replaced for a lower intensity design; and the hangar and blades underneath the curved
inverted vacuum box were also changed to a lower intensity design.

Fig. 18. Post rebuild configuration.

These modifications allowed a 30% increase in secondary headbox flow rate, which was only limited by fan pump
capacity and not by crushing. Burst improved by 6% and there was a slight improvement in CD STFI. Wet end
runnability also significantly improved as a result of the modifications.

SUMMARY

There are often opportunities for significant cost reductions through quality improvements and reduced energy usage
on containerboard grades. Table configurations have evolved with adjustable features to provide flexibility to better
handle the wide range of grade conditions typically seen on many machines. Top formers have also evolved with
engineered geometries to handle higher flow capacities, improve formation, and provide strength enhancements.
Several case studies are presented that illustrate typical table and top former rebuild opportunities and avenues for
strength gains and cost savings for containerboard machines.

REFERENCES

1. Taylor, G. I., “Drainage at a Table Roll and Foil”, Pulp Paper Mag. Can., Vol. 59, pp. 172-176 (1958).

2. Wildfong, V., Shands, J., Ronning, J., Bousfield, D. W., “Prediction of Wire Deflection and Activity
Generation on Single Wire Machines”, proceedings from the 2008 Papercon’08 TAPPI/PIMA/Coating
Conference, Dallas, Texas.

3. Bousfield, D., Wildfong, V., and J. Porter, “ Activity Generation on Single Wire Tables,” TAPPI Spring
Technical Conference Proceedings (2003).

4. Zahrai, S., Bark, F. H., “On the Fluid Mechanics of Twin Wire Blade Forming in Paper Machines”, Nordic
Pulp and Paper Research Journal, Vol. 10(4), pp. 245-252 (1995).

5. Wildfong, V., Shands, J., and J. Ronning, “An Evaluation of a Forming Section Rebuild on the Fluid
Mechanics and Sheet Structure of a Bladed Style Top Former Producing Board Grades,” 63rd APPITA
Annual Conference, (2009).

PaperCon 2012 Page 1810

Wet End Forming Equipment
Rebuilds on Containerboard
Machines for Cost Savings
Jay Shands, Claes Holmqvist, Dean Miller,
Ken Stager, Vaughn Wildfong
Paperchine-JohnsonFoils, Springfield, MA

PaperCon 2012 Page 1811

Challenges

• Decreasing furnish quality

• Increasing speeds
• Market conditions dictating lighter weights
• Optimization over wide range of grade conditions
- Medium to Liner
- Wide range of weights and speeds

PaperCon 2012 Page 1812

Wet End Trends

• Drainage equipment being designed for better control over

shear conditions
- Better formation, greater CD alignment
- Strength enhancements
• Table drainage equipment
- Units upgraded or replaced with adjustable features
• Top formers
- Geometries being re-engineered/modified
- Higher flow capacities at controlled shear conditions

PaperCon 2012 Page 1813

Cost Savings Opportunities from Strength
Enhancements

• Lower fiber usage

• Lower strength additive usage
• Lower refining energy usage
• Increased production rate from lower drying requirements

PaperCon 2012 Page 1814

Stock activity
Affects formation and fiber alignment through shear and
elongation

elongation
shear

• Break-up of fiber flocs, formation and strength improvements

• Fiber orientation randomization
• Activity is axisymmetric (lower ratios)
• Impact depends on fiber network properties (consistency, yield
stress, retention aids etc.)

PaperCon 2012 Page 1815

Traditional Foil

Stock activity from fabric

deflection, acceleration
changes

Fabric

Suction brings water

through fabric creates
vacuum forces
Fabric deflection from
vacuum forces

PaperCon 2012 Page 1816

Adjustable Angle Foils

Stock activity and drainage

variable dependent on foil
angle

Fabric

Suction dependent on foil

angle, speed, and other
conditions
Foil Angle Adjustable

PaperCon 2012 Page 1817

Activity blades
Additional activity and shear generation

• Diverging and Converging Sections

• Two mechanisms
-Diverging angle creates fabric deflection, acceleration forces
-Converging angle forces water back into sheet creating positive pressure
pulse
• Effective formation improvement tool
• Can generate too much shear depending on speed/geometry

PaperCon 2012 Page 1818

Trends – Gravity Units with Adjustable Features
Flexibility for controlling shear over wide speed range

Angle Adjustable Foils

Vertically Adjustable
Activity Blades

PaperCon 2012 Page 1819

Vacuum Dewatering
Traditional “Broken Plane” Pulsative Device

Control blades
lower than table level
Support blades controls fabric deflection
table level and activity

VACUUM VACUUM

PaperCon 2012 Page 1820

Trends - Vacuum Dewatering
Adjustable “Broken Plane” Pulsative Devices

Support Control
Blades Blades

VACUUM VACUUM VACUUM

Control Blades Vertically Adjustable

PaperCon 2012 Page 1821

Multiple Zone Vacuum Boxes
Dryness and Energy Savings Opportunities

17% 19%
15% 10” 17% 10”
14% P 14% P
5”
5”
In Hg
In Hg

Three Single Hivacs Trivac

PaperCon 2012 Page 1822

Case Study 1
Fourdrinier Table Upgrade – 100% OCC furnish

Product: Corrugating Medium

Basis weight: 90 to 200 gsm
Machine speed: 400 to 640 mpm
Furnish: 100% OCC
Headbox Consistency: 0.7% to 0.9%
Retention: 70% to 85%
Freeness: 65 to 70 SR

PaperCon 2012 Page 1823

Table Rebuild
Phase I & II

Single Compartment
Low Vac Boxes Foil Units
Hi Vac Boxes
Before

New New
New Pulsative
(4) Compartment (2) Compartment
Drainage Unit
Hi Vac Box Low Vac Box
Phase I

PaperCon 2012 Page 1824

Table Rebuild
Phase I & II

Single Compartment
Low Vac Boxes Foil Units
Hi Vac Boxes
Before

Results
+1.5% dryness
New New
New Pulsative + 90 mpm
(4) Compartment (2) Compartment
Hi Vac Box Low Vac Box
Drainage Unit - 31% drive load

PaperCon 2012 Page 1825

Table Rebuild
Phase III

New Pulsative Drainage Unit

with Adjustable Control Blades

New Forming
New New Pulsative Drainage Units
Board
DuoFlo

New Ceramics for vacuum control

existing units valves

PaperCon 2012 Page 1826

Affect of Adjustability
170 gsm at 420 mpm

Activity blades Activity blades

at table level lowered
Property Strength Gain
Flat Crush of Corrugating Medium, CMT test 8%
MD Short Span Compression test 4%
CD Short Span Compression test 15%

PaperCon 2012 Page 1827

Table Rebuild
Phase III

New Pulsative Drainage Unit

with Adjustable Control Blades

New Forming
New New Pulsative Drainage Units
Board
DuoFlo

Cost Savings
New Ceramics for vacuum control 30% reduction starch
existing units valves at size press

PaperCon 2012 Page 1828

Table Rebuild
Linerboard Virgin/OCC furnish application

Product: (2) ply linerboard

Basis Weights: 35 – 74 lb/1000 ft2 (170 – 360 gsm)
Speeds: 1150 – 2000 fpm (350 – 610 mpm)
Furnish: Virgin Pine/OCC

PaperCon 2012 Page 1829

Table Rebuild
2 ply linerboard

Before

New Pulsative Drainage Units

with Adjustable Control Blades
New
(2) Zone
Lo Vac Box Dropleg modifications
After

PaperCon 2012 Page 1830

Post Rebuild
Activity

PaperCon 2012 Page 1831

Avenues for Cost Savings
Optimization trials – 56 lb/1000 ft2

Refining constant at Basis Weight constant at

pre-rebuild levels pre-rebuild conditions

• 1% basis weight reduction • 16% lower refining energy

• 10% speed increase • 7% speed increase
• 9% formation improvement

PaperCon 2012 Page 1832

 Optimization 69 lb/1000 ft2
Best results at high activity
2.5

Before Rebuild (ytd avg)

2
Optimization Trial Period
Refining (HPD/T)

(avg)
1.5

0.5
-37%
1360
0
1340
Before Rebuild (ytd avg)
1320
Machine Speed (fpm)
Optimization Trial Period
(avg)
1300

1280

1260 +7%
1240

1220

1200

PaperCon 2012 Page 1833

Top Formers
Example 2 ply linerboard machine with top formers

PaperCon 2012 Page 1834

 Top Former Drainage Capacity and
Properties Often Limited Due to Crushing

Linerboard with Woodfree board

crushing in filler ply crushing single ply sheet

- Slide 25 PaperCon 2012 Page 1835

Pressure Pulse in a Twin Wire Former

Pressure Pulse Pressure Pulse Slows Flow Down

• creates drainage
• creates shear
• some shear helps formation
v • excessive shear hurts formation and
strength

PH DU fabrics
Fiber Mat

Forming fabric

v
Drainage

PaperCon 2012 Page 1836

 Crushing in Sheet

• Caused by high intensity shear

• Hurts most sheet properties
• Limits capacity
• Early twin wire zone elements most critical
- Lead-in box
- Initial inverted box geometry
- Often bottlenecks

- Slide 27 PaperCon 2012 Page 1837

Top Former
Example Rebuild

Product: linerboard and fluting

Basis Weights 100 - 200 gsm
Speeds 730 - 930 mpm
Furnish 100% OCC

Secondary headbox flow rate

limited due to crushing

Target improved burst

PaperCon 2012 Page 1838

 Top Former
2 ply linerboard/fluting

• New jet landing box

• New lower intensity lead-in
box
• Changed inverted box blade
geometry to lower intensity
configuration
• New autoslice

Results
+30% increase in secondary headbox flow rate
+6% improvement in burst
Wet end runnability improvement

PaperCon 2012 Page 1839

Summary
Wet End Rebuilds on Containerboard Machines for Cost Savings

• Containerboard production wet end challenges

- Widely varying grade conditions
Linerboard and medium
Wide speeds and weight ranges

• Table drainage equipment trends

- Drainage equipment being designed for better control over shear conditions
Better formation, greater CD alignment
Strength enhancements
- Units upgraded or replaced with adjustable features

• Top former trends

- Geometries being re-engineered/modified
- Higher flow capacities at controlled shear conditions

PaperCon 2012 Page 1840