According to Jack Allen, Kadant’s tissue applications manager, “tissue creping is an operation near the end of the tissue manufacturing process where bulk, stretch, absorbency, and softness are created in the tissue. Tissue creping is vitally important when these characteristics are key attributes of the final product. Technically, everything can be a factor and affect the tissue creping process.”
Tissue manufacturing from the time the sheet is first formed until you have a jumbo roll of tissue takes less than 2 seconds. The process is simple in many respects, but to get high quality tissue and meet market expectations, you must push the creping envelope. Doctoring systems are crucial to producing a high quality product and not damaging the Yankee shell in today’s high-speed process. The proper chemistry is also a key factor in the process. The variables involved in the creping process are numerous, but if you do not get the doctoring correct, you limit your ability to create a soft and absorbent tissue.
The following case study is an example of how finding the correct variables when tissue creping is important.
Challenge: A tissue manufacturer was experiencing significant slab loss (nearly 10%) due to variations in quality of its product coming off the Yankee creping doctor. The manufacturer produces as many as 30 different grades with 50% of production coming from 9lb bath. Napkin grades are also produced. The standard blade used is made of 1095 steel with an average life of 10-12 hours.
Solution: The CeraEdge L was recommended for its ability to increase blade life over conventional steel, reduce sheet 2-sigma variations in tensile, stretch and caliper (slab loss factors), and produce a softer-to-the-touch sheet.
- Slab loss reduction from 10% to nearly 0%
- Significant reduction in blade wear rate (10 times the life over steel)
- Increase in machine efficiency and operator safety due to
- reduction in blade changes
- Less impact on the Yankee coating as skinning blade did not need to be loaded for wash-ups
- Decrease in 2-sigma variation
- Sheet feels softer-to-the-touch for all grades
Learn more about the tissue creping market by reading the interview with Jack Allen.