“PCA” – Polyclean Applicator the patented application system “ The Cost-effective, continuous keeping clean of Dryer Cylinders and Fabrics through Passivation“

Causes of deposits in the Drying Section Sticky impurities / Stickies from the waste paper Originally small particles accumulate on the dryer fabric and/or cylinders and build up Fiber dust Paper fibers are torn out of the paper surface as a result of the damp paper web adhering to the cylinder, leading to dust in the dryer section and contamination of cylinders. Starch or coating particle deposits after a size press or coater, resin deposits ..............

EXAMPLES

Deposits can lead to various problems Possible effects of deposits Health & Safety (increased hazard potential) Quality problems/ Reclamations Production problems Subsequent problems in converting Dust explosion/ fire hazard Hazard potential from manual cleaning Holes in the Paper Dirt in the Paper Poor moisture cross profile Printability issues Breaks Waste Reduced efficiency/ drying efficiency Shutdowns Breaks Deposits Waste

Treatment concept to prevent or reduce the contamination of the dryer fabric Possible methods Prevent the formation of stickies in the system. (Mass treatment) Clean the contaminated dryer fabrics. Prevent material from the paper web from adhering to the dryer fabric. (Passivation) Which approach is chosen depends on the possible results which can be achieved, in comparison to the expenses / costs.

PCA is inserted into the doctor blade holder What actually is a PCA and how does it work? The PCA is a newly developed application unit which can be inserted into an existing doctor blade holder. existing doctor blade is removed PCA is inserted into the doctor blade holder

What actually is PCA and how does the application work? The PCA applies Polyclean, a specially developed product, permanently and evenly across the width of the treated surface. The resulting passivation of the surface means that: Stickies no longer stick on the cylinder surface. The adhesion of the wet paper web on the drying cylinder is considerably reduced. In this way, dusting and picking is significantly reduced and the plugging of the cylinder is prevented.

Passivation – the use of a light coat of a protective material to create a shell against corrosion (adhesion prevention). A very thin layer of a special passivating agent is continuously applied to the surface to be treated. The coated film prevents sticky substances or paper fibers from adhering to the treated surface and from being torn from the paper / cardboard, and accumulating on the surface of the drying fabric or drying cylinder. The treated surface stays clean much longer or even permanently clean (depending on the degree of contamination before) and possibly cleaning can be reduced to a minimum or may be omitted. In contrast to most cleaning processes, with passivation there is no risk of damage to the treated surface.

Application of the Passivation Agent For the application of the passivation agent, a special application system had to be developed. The main requirements for this system were: A uniform, continuous application of a very thin film over the entire width As few as possible moving or electrical parts? (The environmental conditions are not optimal for the stability of mechanically moving or electrical components) Application to both the cylinder and to the dryer felt No spraying (atomisation, blocking of nozzles etc.) Small footprint (the space for the installation of additional equipment in the drying section is often of limited availability)

PCA Holding plate for insertion into bladeholder Application wick with built in metering Coupling piece for connection to product feed pipe

PCA+ (PCA W/ Blade holder) For applications where in addition to the PCA, a doctor blade is still needed, and for which no double doctor system is present, the PCA+ was developed. PCA Blade holder PCA Loading hose for compressed air controlled loading of the PCA Loading hose for compressed air controlled loading of the PCA Holding plate for insertion into blade holder

PCA Dosing Unit Warning light Control cabinet with possibility of connection to the PLS Automatic air removal Flow measurement and monitoring Filter unit Compressed air control for PCA+ Dosing pump

PCA is inserted into the existing doctor blade holder PCA Installation After the dosing unit has been previously installed, the PCA can be installed without the need for a shutdown. Only a short stop of the machine is required to install the PCA. Existing doctor blade is removed PCA is inserted into the existing doctor blade holder

PCA In Operation PCA Dosage pipe

Example of results of a cylinder treatment without Polyclean with Polyclean

Application examples Initial situation: Passivation of a lead cylinder between press and drying section. Initial situation: lead cylinder with extreme build up high dust level in the beginning of the drying section (every 2-3 hours a cleaning of the pan of the doctor blade holder is necessary) the first 3 cylinders of the drying section are covered with fibers Situation after installation of PCA: cylinders are no longer covered with fibers and stickies dusting in the drying section is eliminated

Application examples Passivation of the first drying cylinder in the drying section Initial situation: drying cylinder extremely clogged downtime due to breaks  2.4% bad moisture cross profile Situation after installation of PCA: no more build up on the drying cylinder downtime reduced to 0.7% reduction of humidity regulation at the nozzle moisturizer from 0-100% to 0-70%

Application examples 3) Passivation of the first roll of a calendar Initial situation: breaks (on average 3 per shift) due to stickies, as a consequence more breakdowns and broke at the calendar lots of stickies on the rolls and as a consequence holes in the paper web Situation after installation of PCA: no breaks and holes, as well as clearly reduced maintenance reduction of expenses, set-up times of calendar rolls, and reduced grinding

Application examples 4) Passivation of dryer fabrics Initial situation: heavy plugging of dryer fabrics significant reduction of the air permeability of the dryer fabric after short duration very short dryer fabric lifetime Situation after installation of PCA: dryer fabrics and its guide rolls are clean significantly better moisture cross profile of the paper significant increase in dryer fabric lifetime

Summary of advantages of PCA application smooth and clean surface of the treated cylinders, rolls and dryer fabrics significant reduction of picking & dusting increased lifetime of dryer fabrics increasing of cylinder temperature is possible less breaks reduced efforts in cleaning and maintenance possible increase of production capacity reduced specific energy consumption better moisture cross profile .....

Advantages of PCA compared to traversing nozzle less maintenance efforts no spraying compact construction size permanent and even application across the complete width of the surface to be treated no additional and troublesome components no electrical drive fewer moving parts no investments or maintenance costs

Procedure when interested in using the PCA Coldwater will review the situation on-site and discuss and document the possibilities of installation with you. You will receive a quotation for the passivation product. When you are interested, an implementation appointment will be arranged. The PCA and the specifically developed dosing system are provided to you free of charge for the duration of use and the application of our product. Therefore, you do not bear any risk, as you do not cover any investment costs for the dosing equipment.

PCA – Polyclean Applicator the patented application system Refernce List PCA 2015-02-02.xls PCA – Polyclean Applicator the patented application system