Sheet Forming and

Formers

Jim Atkins
Atkins, Inc.

TAPPI Paper Machine Operations Course

 Water Removal
Most water removal occurs in the
Forming Section forming section. Since fibers are
5,947 gpm hydrophilic, water removal gets
increasingly difficult.

Press Section
124 gpm

Dryer Section
72 gpm

TAPPI Paper Machine Operations Course

 Types of Formers

Fourdrinier

Hybrid or Top Wire

Twin Wire or Gap

Twinwire or Gap

TAPPI Paper Machine Operations Course

 Board & Packaging – MultiPly Formers

Two ply using

secondary headbox

2
Two ply using mini
top fourdrinier

Three ply using

multiple fourdriniers
2
2

TAPPI Paper Machine Operations Course

 Fourdrinier Terminology
 Typical forming table layout
 Breast roll
 Forming board
 Foil boxes
 Low vacuum boxes
 Flatboxes or high vacuum boxes
 Couch roll
 Wire turning roll
 Wire return rolls (including guide and stretch rolls)

TAPPI Paper Machine Operations Course

 Fourdrinier Basic Functions
 Forms and consolidates the fibers into a web
 Increase consistency of the sheet from <1% at the
slice to 20-25% at the couch.
 Retain the fiber and filler – typically around 85%
first pass retention.
 Provide the best Z-direction uniformity possible –
one of the limitations for fourdrinier machines.
 Transfer the sheet into the presses.

TAPPI Paper Machine Operations Course

 The Problem of Flocculation
 Most papers formed at
less than 0.7%.
 Fibers like to form
networks call flocs.
 Flocs result in lumpy
paper, poor formation.

TAPPI Paper Machine Operations Course

 Forming Process

Forming is a combination of three hydro-dynamic

processes:

Drainage Oriented Shear Turbulence

 Each occurs simultaneously and can be controlled within limits by

the papermaker.
 It is the control of these processes that will ultimately determine
the characteristics of the paper produced.

TAPPI Paper Machine Operations Course

 Forming Process
Drainage

TAPPI Paper Machine Operations Course

 Forming Process
Drainage

TAPPI Paper Machine Operations Course

 Controlling Slice Flow
 The way the jet hits on
the forming wire
controls initial fiber mat
formation.
 Retention of fines and
filler depend on good
mat formation.

TAPPI Paper Machine Operations Course

 Controlling Slice Flow
 L = bottom lip extension
 b = slice opening
 L/b ratio.
 L/b determines jet
angle.
 Velocity forming vs.
pressure forming.

TAPPI Paper Machine Operations Course

 Pressure forming vs.
Velocity Forming

TAPPI Paper Machine Operations Course

 Shear at slice impingement
 The speed of the jet leaving
the headbox can be faster or
slower than the forming
fabric
 This creates shear on the
bottom side of the jet
 This speed difference is
called rush/drag or jet-to-
wire
 It can stated as a speed ratio
or as the exact speed
difference in fpm
Point of shear

TAPPI Paper Machine Operations Course

 Forming Process
Turbulence
 Turbulence is
added to the
forming zone to
minimize floc
formation
 Turbulence doesn’t
last.
 Smaller the scale,
faster it dissipates.
 Must constantly be
added
TAPPI Paper Machine Operations Course
 Forming Board
 First drainage
element on the
former
 First blade is wider
and has a rugged
mount system
 Blades are flat
(usually)
 Gap should open up
as the front wall
follows down the
breast roll

TAPPI Paper Machine Operations Course

 Forming Board
 Supports the
forming fabric
 Catches the
headbox jet
 Must be very rigid to
avoid deflection and
vibration under load
 Usually fix mounted Weavexx Adjustable FB
but some models
can be moved on
the run

TAPPI Paper Machine Operations Course

 Forming
Two examples of jet delivery over the forming board

Case 1 Case 2

TAPPI Paper Machine Operations Course

 Foil Unit

Blade angles are fixed. Must be removed

to change the angle and stock activity.
TAPPI Paper Machine Operations Course
 Gravity Foils - Concept
Machine Direction
Slurry Activity
Mat
Forming Wire
Suspended Layer
Foil Blade

Dewatering
Positive

Foil Pressure Profile

0
Negative

TAPPI Paper Machine Operations Course 20

 Blade Spacing

Pulse Profile

TAPPI Paper Machine Operations Course

 Relationship Between Foil
Spacing And Pulse Frequency

Frequency (Hz) = Fabric Speed (mpm)

.06 X Blade Spacing (mm)

<30 Hz Difficult to agitate stock

30-40 Historical design standard
80-100 Hz Present design standard
100 Hz Maximum possible for fourdrinier
150+ Hz Gap or top-wire formers
TAPPI Paper Machine Operations Course
 Operation of Foils
 Foil blade angles and widths are variables used
to develop controlled activity.
 Maximum foil angle of 3 degrees for slow
machines and typically 0.5-1.0 degrees on fast
machines.
 Experience and trial and error is used to find the
right set up
 Goal is fine scale turbulence and controlled
drainage
 Long fiber furnish is more difficult to agitate
TAPPI Paper Machine Operations Course
 Examples of Activity Level

MD

Low

Transition High
TAPPI Paper Machine Operations Course
 Foil box activity
Initiate Activity Maintain Activity

Note the two different types of blade construction

TAPPI Paper Machine Operations Course
 Moveable Angle Foil Units

IBS Hydroline foil units with adjustable

angles and height.
TAPPI Paper Machine Operations Course
 Low Vacuum Boxes

Bottom discharge Lovac

• high flow capacity
• low P potential
• require pan depth or modification
to w/w tray for leg height

End discharge Lovac

• low flow capacity
• high P potential
• can fit in shallow pan area
• require space on back side
of machine for drop leg

TAPPI Paper Machine Operations Course

 Low Vacuum Boxes
 Lovacs take over at 2-3%
consistency.
 Lower drag and energy
than high vacs.
 Capable of up to 10%
consistency (6% more
common).
 Use blower for vacuum
needs-- 5-50” water. Bottom discharge

TAPPI Paper Machine Operations Course

 Low Vacuum Boxes
 Low vacs should be Vacuum Blower
connected to a separate
vacuum blower.
 Each box needs a
separator.
 Special control valves
designed for low
Vacuum
vacuum operation are
Header for
normally used Low Vacs
 Alternately a hand valve Separator w/
can be used on the box Drop Leg
to bleed air into the box
reducing the vacuum

TAPPI Paper Machine Operations Course

 Low Vac Operating Limits

Lovac Body Forming fabric

Wire to
vacuum inlet Vac
In
Wire to overflow

Maximum
Allowable Drop
Vacuum Leg

Seal Pot

TAPPI Paper Machine Operations Course

 Low Vac Operating Limits

Vacuum exceeds
maximum allowable

TAPPI Paper Machine Operations Course

 Pulsative Drainage Units
 Controlled activity without sealing the
sheet.
 Early attempts with lovacs after the
forming board unsuccessful.
 Two types of pulsative drainage units
 broken plane
 step foils

TAPPI Paper Machine Operations Course

 Broken Plane Unit

TAPPI Paper Machine Operations Course

 Step Foil Unit

TAPPI Paper Machine Operations Course

 Moveable Element Lovac Units

IBS Varioline flovac units with height

adjustable t-bars and control blades.
TAPPI Paper Machine Operations Course
 Flatbox (Hivac) Operation
 Take over from lovacs
 Vacuum levels of 5-50
kPa (1.5-15”Hg)
 Consistency of 14-19%
before couch
 High drag load so want
to minimize the number
of boxes
 High quality ceramic
covers a must on high
speed machines

TAPPI Paper Machine Operations Course

 Flatbox (Hivac) Operation

TAPPI Paper Machine Operations Course

 Couch
 Vacuum of 15-25” Hg
 Takes the sheet from 16% consistency up to 22-24%.
 Consolidates the sheet.
 Shower water 1.6 gpm/100”
 Rewetting
 outgoing side past deflector
 incoming side past the wipe
 Double doctors result in drier sheet to presses

TAPPI Paper Machine Operations Course

 Couch Rewet

TAPPI Paper Machine Operations Course

 Double Doctor On Couch

TAPPI Paper Machine Operations Course

 Forming Drainage Elements
Couch Roll Setup
Full Width Correct Setting,
Sheet Rewetting Packing Strips Throw-Off goes in
Saveall

Hi Lo
Vacuum Box Vacuum Box

Saveall
Saveall

Couch Roll Adjustment

Deckle
Worn Gear
Adjusters
Adjuster

Couch Roll Vacuum Box Adjustment

TAPPI Paper Machine Operations Course

 Forming
Example of Good Couch Throw-off

TAPPI Paper Machine Operations Course

 Sheet Forming and
Formers

Jim Atkins
Atkins, Inc.

TAPPI Paper Machine Operations Course