Value Adding Processes in Converting
The base sheet for a tissue product is primarily designed in the papermaking process by
the selection of appropriate furnish and process steps. It is often improved in the rewinding and converting processes for imparting the desirable attributes for aesthetics, functionality, or just convertability. Such processes, if designed on a sound technical base, impart substantial value to the tissue at only a nominal equipment and running cost. These processes, therefore, are appropriately termed as the Value Adding Processes. Other terms used instead are Finishing Processes, Mechanical Treatment and Post-Treatment.
The engineering and support services for the Value Adding Processes are available from WEBCON in association with EMBOSSING TECHNOLOGIES.
VALUE ADDING TECHNOLOGIES
The following technologies are supported:
CALENDERING for handfeel improvement and caliper control: - Steel-to-steel
- Steel-to-rubber
- Hot calendering
EMBOSSING for aesthetics, absorbency and bulk enhancement- Steel-to-steel
- Steel-to-rubber, also known as texturizing or blind-embossing
- Steel-to-Paper
LAMINATING two or more plies - Non-Embossed
- Flexo-printing
- Cold-glue spray
- hot-melt
- Embossed
- Nested registration
- Point-to-point registration, also known as pin-to-pin,
- Random registration, also called DERL
PLY BONDING to alleviate sheet separation
- Mechanical
- Spot embossing
- Linear tracks
- Hot Melt
- Cold glue
- Gravure printing
- Atomized spray
EQUIPMENT DEVELOPMENT
- Equipment design (See "Crowning" in Papermaking Section)
- Roll design
- Bearing support and drive system
- Roll crowning (See "Crowning" in Papermaking Section)
- Crown calculations
- Crown correction
- Wedge design and gap readouts
- Pattern Development
- for aesthetics
- for attribute enhancement
- Engraving support
- Chemi-mechanical engraving
- Laser engraving
PROCESS DEVELOPMENT
- Threading route design
- to ease threading
- to reduce tendency to wrap-ups
- to locate spreader rolls to eliminate wrinkles
- to minimize bulk and stretch loss
- Set point development and benchmarking
- Gap settings
- Roll speeds and draws
- Spreader roll angle
- Testing paper properties
- Base sheet
- Finished product
- Product in storage and on the shelf
- Recommendations for base sheet changes
- to meet or enhance the attribute targets
- to balance sheet development between papermaking and converting to minimize brand cost
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