CRESCENT FORMER The Crescent Former is the culmination of technological improvements derived from our experience in the manufacturing of four machines since the 1960s (Plain Wire; Sloped Wire; Twin Wire C-Former; and Twin Wire S-Former). The first Crescent Former was invented in the 1970s by the multinational Kimberly Clark which held the patent until the Nineties. Our technological innovations and more than 50 years of experience in the field of tissue ensure the highest levels of performance from the Recard Crescent Former. Each Recard Crescent Former is designed to optimize the real operating speed of your production line. We have achieved performance of over 2000 meters per minute.

1. Crescentformer
Forming Presentation

2. Agenda
•1/ Fabric Design:
– Warp Bound Triple Layer (Enterprise)
•2/ Key Operating Variables
– Sheet Trim Method / Fabric Width Considerations
– Operating Tension
– Jet Impingement
•3/ Showering:
– Showering Best Practices

3. FABRIC DESIGN

4. Crescentformer
Forming Fabric Design Criteria
Drainage:
• fabric must be open enough to handle high dewatering loads
• speed, formation, tensile ratio
Fiber Support
• fabric must be fine enough to retain fiber, build sheet
• retention, pin holes, tensile
Stability / Durability
• width stability critical on Crescentformers
• wear potential for life

5. Conventional Triple Layer
Reported as Open Area
Blocked by Weft Binders
Paper Making Surface
• Enterprise at 450cfm WILL OUT DRAIN other products at +550cfm
• in conventional weft bound fabrics, considerable amount of
reported Open Area actually blocked by binder
• no extra binder yarn in Enterprise
• open structure for ease fast dewatering, ease of cleaning
MD

6. Conventional Triple Layer
Binder Wear
Weft Binding
• delamination with conventional WEFT bound fabrics limits life
• warp bound Enterprise will not delaminate
• longer life potential

7. Warp Binding
CDL-4 DAR (Marking)
CDL-4 SAR (Non-Marking)
CDL-4 WEAVE COMPARISON
• take existing bottom MD warp yarn to bind

8. Warp Binding
Patented Enterprise Design:
• More Open than conventional Triple Layer and Double Layer designs.
• Faster drainage
• Dryer sheet off the former / machine speed
• Sheet formation (flocs)
• Higher Fiber Support than other designs:
• Fiber retention
• Sheet tensile
• Pin holes / formation
• Better Life potential than other designs:
• No delamination with warp binding
• Excellent wear potential
• Improved width stability with use of comparable weft diameters

9. Comparison of Specifications
P621 / T521 Enterprise 2184 - Fine Enterprise 2184 - Coarse
WEFT Binding WARP Binding WARP Binding
Mesh - Total (/inch) 188 x 120 184 x 165 184 x 141
Mesh - Top (/inch) 94 x 80 92 x 110 92 x 94
Mesh - Bottom (/inch) 94 x 40 92 x 55 92 x 47
Warps (MD) 0.125mm 0.127mm 0.127mm
Wefts (CMD) 0.15mm 0.11mm 0.13mm
0.11mm
0.25mm 0.21mm 0.25mm
Caliper 0.027" 0.024" 0.026"
Permeability 490 cfm 450 cfm 480 cfm
Open Area 30.0% 36.7% 36.3%
Drainage Index 39.2 DI 49.5 DI 45.1 DI
Frame A (MD x CMD) 0.178 x 0.686mm 0.121 x 0.437mm 0.140 x 0.437mm
Frame B (MD x CMD) 0.178 x 0.145mm 0.121 x 0.155mm 0.140 x 0.155mm
MD Frame Length 0.178mm 0.121mm 0.140mm
Fiber Support Index 138.1 FSI 187.0 FSI 165.6 FSI
Support Points (/inch2) 3760 6600 5640
Conventional
Triple Layer

10. Stability Benefits - Enterprise
0
100
200
300
400
500
600
700
800
900
Gemini
Plus
2184-Fine Polaris 2184-
Coarse
mN
mNm

11. Tissue References - The Americas
Machine # Former Width Grades BW Furnish Speed Fabric(Outer)
1 3 CrescentFormer 110 Tissue 9.5-12 Waste 5600 Gemini Plus
2 3 CrescentFormer 254 Tissue/Towel 9.5-27 Kraft 4600 Enterprise
3 3 CrescentFormer 110 Tissue/Towel 9.5-12 Waste 5500 Enterprise
4 9 CrescentFormer 202 Tissue 9.5-11 Waste 5500 Enterprise
5 20 CrescentFormer 280 Tissue/Towel 9.5-15 Waste 5500 Polaris
6 5 CrescentFormer 310 Tissue 9.5-11 Kraft 5600 Polaris
7 1 CrescentFormer 130 Tissue 9.5 Kraft 5500 Enterprise
8 1 CrescentFormer 206 Tissue 9.5 Kraft 5500 Enterprise
9 2 CrescentFormer 210 Tissue 9.5 Kraft 5500 Enterprise
10 18 CrescentFormer 200 Tissue/Towel 9.5-13 Waste/Kraft 5700 Enterprise
11 1 CrescentFormer 80 Tissue 9.5-11 Waste 4000 Enterprise
12 2 CrescentFormer 80 Tissue 9.5-11 Waste 4000 Enterprise
13 3 CrescentFormer 110 Tissue 9.5-11 Waste 5000 Enterprise
14 1 CrescentFormer 172 Tissue 9.5-11 Kraft 5500 Enterprise
15 1 CrescentFormer 172 Tissue 9.5-11 Kraft 5500 Enterprise
16 1 CrescentFormer 132 Tissue 9.5-11 Waste/Kraft 4500 Enterprise
17 2 CrescentFormer 132 Tissue 9.5-11 Waste/Kraft 4500 Enterprise
18 2 CrescentFormer 173 Tissue 9.5-11 Kraft 5500 Enterprise
19 1 CrescentFormer 209 Tissue 9.5-11 Kraft/Waste 5700 Enterprise
20 1 CrescentFormer 220 Tissue 9.5-11 Kraft/Waste 5500 Enterprise
21 2 CrescentFormer 220 Tissue 9.5-11 Kraft/Waste 5500 Enterprise
22 11 CrescentFormer 200 Tissue 9.5-12 Waste 6000 Polaris/Enterprise
23 3 CrescentFormer 140 Tissue 9.5-13 Waste 5500 Enterprise
24 3 CrescentFormer 145 Tissue 9.5-11 Waste 5500 Enterprise
25 1L CrescentFormer 171 Tissue 9.5-11 Waste/Kraft 3500 Polaris
26 11 CrescentFormer 110 Tissue 9.5-13 Waste 5000 Polaris

12. Mill: Midwestern US
Machine: 202” Crescentformer
Grades: 9.5 - 13# (15 - 20 gsm)
Furnish: 100% Waste Furnish (high ash content)
Speeds: 5800 ft/min (1765 m/min)
Fabrics: Enterprise 2184 preferred product
Improved retention and formation
Excellent drainage and wear potential
Improved sheet CMD profile
Trim Beads
Case Study #1

13. Mill: Mexican Mill
Machine: 150” Crescentformer
Grades: 9.5 - 13# (15 - 20 gsm)
Furnish: Waste / Kraft Furnish
Speeds: 5750 ft/min (1750 m/min)
Fabrics: Enterprise 2184 preferred product
Excellent formation / tensile
Improved sheet properties over other deigns
Trim Beads
Case Study #2

14. Mill: Eastern US Mill
Machine: 210” Crescentformer
Grades: 9.5 - 13# (15 - 20 gsm)
Furnish: 100% Waste Furnish (Low quality, dirty)
Speeds: 5900 ft/min (1800 m/min)
Fabrics: Enterprise 2184 preferred product
Improved drainage / formation
Runs cleaner than other designs
Trim Beads
Case Study #3

15. Defining Sheet
Edges

16. Defining Sheet Edges
Not possible to locate Trim Squirt on Forming Fabric,
as is common practice on other Former types:
– Locate Trim Squirt on felt:
• poor sheet edge
• felt filling
– Trim Sheet Using Plastic Fabric Edges
– Trim Beads

17. Extruded Edges
•1cm and 1” widths common
• provides a straight inner edge for sheet trim
• protective shield recommended
Headbox
Fabric
Extruded Edges
Fabric Edges
inside Headbox

18. Sheet Trim – Trim Beads
–at Yankee, Creping Blades see a temperature step
change where sheet ends
– Crepe blade wears at this point.
• if in sheet, edge tears and breaks.
• if in Shaving, reduced sheet breaks and blade changes
- No sheet Trim to Yankee
- temperature step change at sheet edge
- sheet trim to Yankee
- Temperature step change in Shaving
Sheet on Yankee
Yankee
Crepe Blade

19. Trim Beads
Plastic beads extruded inside fabric edges:
 locate 1.5 – 4cm inside fabric edges.
 generates sheet Trim / Shaving
 durable Polyurethane withstands Chemical attack.
5mm
mmm
mmm
mm

20. Protective Shield
HP Shower Boom
Protective Pan
Fabric (Blue Edge Glue)

21. OPERATING
VARIABLES

22. Crescentformer Adjustments
BR - FR Gap
-25 – 30mm common
- uniform front/back
Separation Angle
(3 – 70 common)
• Jet / Wire Ratio
• Jet Impingement
Fabric Tension

23. Headbox Considerations
• Consistency: Low = Best Formation (0.1 - 0.3% common)
– Low HB consistencies = higher drainage load on fabric
– No different from other Former configurations
• Jet / Wire Ratio: rushing the jet can “pick” the felt surface
– Limitations on using jet/wire to control tensile
– Increases the benefits of fast draining fabric design
• Jet Impingement Angle: angling too much into felt can result
in “picking.”
– Again, limitations here increase importance of fabric design
– Must be fast dewatering
– At same time, must have high FSI to optimize retention / pin holes

24. Jet Impingement Angle
Forming Roll
Breast Roll
Breast Roll
Forming Roll
Excessive
Impingement
Angle
Correct
Impingement
Angle

25. Jet Impingement
Measurement

26. Fabric Tension
• Dewatering a function of Fabric Tension:
D = T / R
D = Drainage
T = Fabric Tension
R = Radius of Forming Roll
• Use as much tension as is needed to get
desired dewatering rate:
– sheet formation
– CD Tensile (MD/CD Tensile Ratio)
• Typical Tensions 35 - 55 PLI

27. WIRE TENSIONING
• Operating Tension:
– single Layer Fabrics - 30 - 40 PLI
– multi-layer Fabrics - 35 - 55 PLI
• Tension Measurement:
– Huyck Tensometer still industry standard.
– different curves for different fabric styles.
– curves for all fabric designs converge above
about 40 PLI.

28. Tensiometer CurveVoith Fabrics - Tension vs Huyck Reading
0
10
20
30
40
50
60
70
80
90
100
110
120
130
140
2184 Avg.
2164 Avg
852 Avg
2152 Avg
Prod. Graph
Avg. 28.857 56.429 75 83.714 90.857 96.75 102.5 107.5 107
Avg 40.359 59.897 75.436 84.872 93.04 98.877 103.13 107.49 111.76 113.86 117.17
PLI 5 10 15 20 25 30 35 40 45 50 55 60
Saturn
Gemini Plus
2164
2184
Average

29. SHOWERING

30. Typical Showering
• Inside HP Fan (150 – 250 psi)
• HP Needle (350 - 500 psi)
– Face Side preferred
•Flooded Nip Shower (Volume)
• Edge Showers
• Barrier Chemical Shower
– Application Rate (ml / min)
– Need for Caustic Stripping

31. Showering – Best Practice
Flooded NipHP Needle Shower
HP Fan
Chemical
Shower

32. Showering – Best Practice
Flooded Nip HP Needle Shower
HP Fan
Chemical
Shower

33. Needle Showering
Inside or Outside ?
Typical Stickie
- paper side of fabric
- forms at yarn cross-overs
- blind to Inside HPS
- inside HPS even less
effective with multilayer
fabrics

34. Needle Showers
Effective Against Stickies
Typical Stickie
- need HP Needle

35. Needle Showers
Distance from Fabric
0-4” 4-8” Beyond 8”
Effective
Cleaning
Distance

36. Needle Showers
Location to Rolls
2 - 5” Common
Locate close to Roll
- support fabric
- wasted shower pressure
- fabric damage

37. Needle Showers
Angle to Fabric
10 – 20o
Angle into Fabric Run Direction
- OUTSIDE HPS
- maximize impact energy
- “chisel” contaminants”

38. Needle Showers
Damage to Fabrics
Excessive Pressure
Poor Oscillation

39. Needle Showers
Damage to Fabrics
Macro view of High-Pressure damage to fabric surface

40. Flooded Nip Shower
Fiber Contamination
Typical Fiber Carryback
- High Pressure Fan
- Flooded Nip

41. Flooded Nip Showering
Volume Calculation
RVV = C x W x S x V
C = fabric caliper (inches)
W = fabric width (inches)
S = fabric speed (ft/min.)
V = fabric percent void (use 0.6)
* 100% of RVV not needed, depending on speed of machine.
At +5000 ft/min, as little as 70% of RVV can be effective.

42. Chemical Showering
Rate of Application:
• can not add faster than chemicals being worn off by HPS
• uniform application (shower nozzle conditions)
apply cleaning chemicals:
Solvents
Caustic wash-ups
• effect on fabric monofilament
• effect on extruded edges / Trim Beads

43. Fabric Life
Considerations

44. FORMING FABRIC LIFE
• Normal Failure Points
– Wear
• Roll Side or Sheet Side
• Caliper Loss Measurements
• Seam Issues (single layer designs)
• Typical Life
– Single Layer: 45 - 75 days
• stability issue / seam issues
– Multi-layer Designs:+75 days
• Damage most common limitation

45. Wear Profiles
AMERICAN TISSUE ST. HELENS, OREGON
.0150
.0160
.0170
.0180
.0190
.0200
.0210
.0220
.0230
.0240
0
18
36
54
72
90
108
126
144
162
180
198
216
234
252
WIDTH (INCHES)
CALIPER(INCHES)
ORIGINAL
USED
SAFE WEAR
MACHINE #3-CRESCENT FORMER
FRONT
#15531

46. Hour-Glassing

47. Drag Wear
MD
Wear Burrs on trailing edge of CMD knuckles

48. Roll Wear
Wear Burrs on all sides of CMD knuckles
Roll corrugation probable