1. 1 Adding & Preserving Quality - Finishing & Converting Balbir Singh & Carl Ingalls Tissue World Americas 2002

2. 2 Solid Mech. Mech. E. Ind. E. Chemistry Chem. E. Mech. E. Paper Machine P/M Dry End Wet End ConvertingPackaging Fluid & Semi- Fluid State Solid State Crepe Doctor Changing Role of Converter

3. 3 Finishing Processes Embossing Ply bonding or laminating Lotionizing Printing Calendering

4. 4 Finishing in Converting Paper Machine Wet End P/M Dry End “Converting”Packaging Crepe Doctor Practical location for finishing processes The converter’s domain Alternate location for calendering

5. 5 Why Calender? Bulk Reduction Bulk Leveling Bulk Reduction Handfeel Gain

6. 6 Calender Nip Crowning Zero-Crown Skewing Nip-Control

7. 7 Calender Gap Control Load activated For handfeel Against stops Bulk control

8. 8 Handfeel Quality Curves HF gain Bulk loss Bulk Before calendering Gain or loss, relative to the base paper. Actual values of product properties. More calendering Target HF Base paper HF HF Before calendering More calendering

9. 9 Finishing Is a Balancing Act Handfeel Bulk Calendering Bulk Strength Embossing Handfeel Absorbency Lotionizing

10. 10 Process Control Curve – Embossing Nip Line Load (pli) No embossing (base sheet) More embossing Base CDT Embossed CDT Embossed Bulk Base Bulk Base MDT Embossed MDT Operating range

11. 11 Quality Control Curve – Embossing Bulk Base paper bulk & CDT (before embossing) CDT CDT range Bulk range Target Window

12. 12 Converter’s Needs Bulk Stretch Strength PP F F e b

13. 13 Variability Uneven Bulk Tapered Reel Uneven Rolls Uneven strength Poor tracking Sheet breaks Holes & Nicks Sheet breaks Poor quality

14. 14 Reel Mechanics Reel Radius Layer Pressure Tensile Stress Nip Pli Bulk

15. 15 Reel Types Secondary Arm Reel Linear Reel

16. 16 Bulk: Thickness Under Pressure Pressure Bulk Embossing crushed, but not crepe. All 3 sheets crushed. Flat Creped Embossed Embossing is not crushed.

17. 17 Product Properties Bulk – fullness, thickness under pressure. Strength – resist failure during use. Absorbency – remove liquid. Handfeel – smoothness, cushion, drape. Ply count – implies quality. Visual appeal – implies quality. How the user will experience the product.

18. 18 Rewinders Two-Drum Horizontal Rail 2-Nips Weighting/Un-weighting Drum Speed Differential One-Nip One Speed

19. 19 Tissue Winders Center WinderSurface Winder

20. 20 Folder Longitudinal Fold Plows Transverse Fold Rollers

21. 21 Draw Rolls Dancer Rolls Calender Rolls Bowed Roll Combating Tools

22. 22 Grouping Combating Tools 1. Unwind Stand 2. Embosser Stand Dancer Skew Roll Nip Rolls Embosser Bow Roll Tension Roll Draw Rolls Bow Roll

23. 23 A Diagnostic Tool 0.50 Bulk Base paper bulk & CDT (before embossing) CDT 050100150200250 0.10 0 0.20 0.30 0.40 Target Window CDT range Bulk range

24. 24 Comparing Embossing Curves A B C 0.50 Bulk CDT 050100150200250 0.10 0 0.20 0.30 0.40 CDT range Bulk range

25. 25 Specifying the Base Paper Window for Embossed Product Properties Window for Base Paper Properties CDT range Bulk range Bulk CDT

26. 26 Conclusion Finishing Finishing adds quality during converting. Focus on end-use properties. Manage tradeoffs between properties. Use Finishing Curves: - set base specs - centerline process - diagnose problems Converting Converting should start at crepe doctor. Make the reel uniform and soft. Avoid rewinding. Match equipment with the product. Provide necessary combating tools.