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Edge Control Systems Edge Control Systems Edge Control Systems Coldwater provides two types of wet end edge control devices: - Fab Curl - Edge Spreader Deckle Board Wet End Products – Edge Control Devices Coldwater engineers and manufactures state-of-the-art edge control systems and provide installation services. FabCurl Edge Control and Wave Management. Eliminate or manage the location of edge waves. Edge Control Systems What is the FabCurl? The FabCurl is an edge controlling system that is comprised of three separate components: • Cheeking Piece Extension • Curl Block • Baffle Blade. These three components work together to eliminate and/or control the edge waves on the wet end of a paper machine. Edge Control Systems Equipment Examples: Cheeking Piece Extension Curl Block Baffle Blade Edge Control Systems What Causes edge waves? There are three main causes: - Stock Expansion - Boundary Layer - Equipment Misalignment Edge Control Systems Stock Expansion MD Edge Waves Created Stock Bounces Off Curl Block Or Deckle Board Headbox MECHANISM (1) Expansion Edge Control Systems Boundary Layer MD Edge Waves Created Stock Slows Due to Boundary Layer Headbox MECHANISM (2) Boundary Layer Edge Control Systems How does the FabCurl stop and control edge waves? Edge Control Systems Using the liquid stock’s tendency to spread out and expand, the Cheeking Piece Extension guides stock to the outside of the machine. This allows for a smooth transition from the headbox to the edge of the wire. Headbox Wire Cheeking Stock Piece Flow Extension Edge Control Systems The Curl Block is positioned under the wire and curls the wire edge up to prevent the stock that has been directed to the sheet edge from the Cheeking Piece Extension from flowing off the edge of the table. Curl Block Headbox Wire Cheeking Stock Piece Flow Extension Edge Control Systems To prevent the stock from rebounding off of the Curl Block and creating a wave, the Baffle Blade is positioned inside the Curl Block and stops the stock from rebounding. The stock is then channeled between the Baffle Blade and Curl Block sending it straight down the table and thus eliminating the edge waves. Curl Block Baffle Blade Headbox Wire Cheeking Stock Piece Flow Extension Edge Control Systems This cross section shows how the Baffle Blade works as stock flows and expands to the sheet edge and is prevented from forming a rebound wave. Edge Control Systems The Result… Edge Control Systems From this point the Baffle Blade can be used to create a small wave that directs the stock to low spots in the sheet profile. We have found that by controlling this small wave the best profiles are obtained. Curl Block Baffle Blade Headbox Wire Cheeking Stock Piece Flow Extension Edge Control Systems Benefits of the FabCurl: - Eliminates/Controls Edge Wave(s) - Custom Engineered Mounting Brackets - Robust Mounting Stands and Brackets - Quick and Easy Removal for Wire Change - Adjustable On The Run - Clean Running System (Can Reduce Breaks) - Can Increase Machine Efficiency Edge Control Systems Eliminates/Controls Edge Wave(s) Before After Edge Control Systems Custom Engineered Mounting Brackets Edge Control Systems Robust Mounting Stands and Brackets Edge Control Systems Quick and Easy Removal for Wire Change Edge Control Systems Adjustable On The Run Showers Vertical Adjustment Horizontal Adjustments Baffle Blade Mounting Stands Curl Block Fully Adjustable and Designed for Easy Removal For Wire Change Edge Control Systems Clean Running System Edge Control Systems Can Increase Machine Efficiency Side with FabCurl Before After Edge Control Systems Can Increase Machine Efficiency Examples: • Reduced CD 2 sigma BW variation by 55% (Bleached Board) • Reduced CD 2 sigma BW variation by 70% (Bleached Board) • Reduced CD 2 sigma moisture variation by 70% (Pulp) • Reduced CD 2 sigma moisture variation by 60% (Pulp) • Reduced CD 2 sigma moisture variation by 50% (Carton) • Increased salable production by 1% (Liner Board) • Eliminated picking on lump breaker (Liner Board) • Reduced edge cockle complaints by 87% (Gypsum) • TSO angle improved from +/- 11 to +/- 6 (Copy Paper) Edge Control Systems Competition FabCurl: Today, there is no equipment that is a direct competitor to the FabCurl. Coldwater is the only company that supplies this technology. Edge Control Systems Edge Spreader Deckle Board Wet End Products – Edge Control Devices Coldwater engineers and manufactures state-of-the-art edge control systems and provide installation services. Deckle Boards Help control stock as it exits the headbox. Results in improved basis weight, moisture, and TSO angle profiles. Edge Control Systems What is an Edge Spreader Deckle Board? The Edge Spreader Deckle Board is an edge control system that is made from UHMW plastic utilizing a Teflon insert to create a seal with the wire and a built-in hinge to help direct stock on the sheet edge. It is not intended to eliminate edge wave, however is can reduce and control them. Edge Control Systems Equipment Description: Edge Spreader Machined Deckle Board Hinge Teflon Insert Edge Control Systems Exiting the head box, the stock is first held straight in the machine direction prior to the machined hinge. Using the machined hinge, the deckle board is angled out on the down stream end to the edge of the wire. This allows the stock to use its natural tendency to spread out. The hinge can also allow the deckle board to be adjusted to direct stock where desired on the sheet edge. Stock Machined Hinge Edge Spreader Deckle Board Flow Headbox Wire Edge Control Systems Benefits of the Edge Spreader / Deckle Board: - Custom Engineered Mounting Brackets - Robust Mounting Stands and Brackets - Quick and Easy Removal for Wire Change - Adjustable On The Run - Clean Running System (Can Reduce Breaks) Edge Control Systems Custom Engineered Mounting Brackets Edge Control Systems Robust Mounting Stands and Brackets Edge Control Systems Quick and Easy Removal for Wire Change Edge Control Systems Adjustable On The Run Edge Control Systems Clean Running System Edge Control Systems The Result… Edge Control Systems Competition Edge Spreader Deckle Board: There are many companies worldwide that can supply deckle boards, but it is how Coldwater’s Edge Spreader Deckle Board uses its Teflon seal that sets it apart from the rest. Edge Control Systems Competition Water Deckle Basic Setup and Function Water Deckle Water Nozzle Flooding Channel .03in (.8mm) Stock Wire Edge Control Systems Competition Water Deckle Issues 1.) Nozzles can build-up with stock which can fall off and cause breaks. •Drop in water pressure and/or improper set height allow stock to leak into channel. •Stock builds-up on nozzle, which can fall off and cause sheet breaks. Edge Control Systems Competition Water Deckle Issues 2.) UHMW deckle board expands from heat and cause damage to wire. •Deckle height is set to .03in (.8mm) when cold. •Steam and hot stock cause the deckle board to expand and contact the wire. .03in (.8mm) Edge Control Systems Competition Water Deckle Issues 3.) Nozzles can clog and allow stock leaks. •Mill water is not always filtered well enough which can cause the nozzles to clog and water flow stops. •With no water flow there is no more seal and stock leaks occur. Edge Control Systems Competition Angled Teflon Seal Basic Setup and Function Deckle Board Teflon Wire Stock Teflon Physical Contact to Wire Edge Control Systems Competition Angled Teflon Seal Basic Setup and Function 1.) A large amount of force is needed to create the same seal as vertical Teflon seal. •Pressure = Force ÷ Area •A larger amount of force is needed for sealing because of the larger area contacting the wire. •The additional force on could pinch and damage the wire. Edge Control Systems Competition Angled Teflon Seal Basic Setup and Function 2.) Typical setups do not have adjustable Teflon strips. •Large amount of pressure on Teflon causes it to wear fast and stock to leak. •Teflon needs to be replaced more often since it wears fast and can not be adjusted. Edge Control Systems Fab Curl and Deckle Board Options - High Wear Materials (i.e. CW5000 Curl Block) - Hinged Stands (Typically Quoted Standard Now) -Additional Showering -Other Customer Requests Edge Control Systems Hinged Stands Edge Control Systems Additional Showering Edge Control Systems Other Customer Requests Edge Control Systems Which Unit is Right For My Machine? - What issues do you have with the current deckle arrangement? - What are you hoping to accomplish w/ an edge control system? - Are deckle waves an issue for your machine? - Are you looking to solve profile issues or other issues (such as cracking) on the sheet edge? - Coldwater will make a recommendation based off qualifying info for unit type, length, etc. Edge Control Systems What do we need to quote? -Drainage Survey -Min. and Max. Slice Openings Used -Machine Speed -Paper Grades Run -What Unit to Quote (Deckle Board or FabCurl) -Any Additional Options Needed/Desired Edge Control Systems After we Receive a P.O. - Need to find the date of the next available outage for scheduling a Measure-Up - Must begin coordinating with the correct mill personnel for Installation Needs •Crane for Bringing Equipment up to Table •Equipment Staged near Installation •Pipe Fitter and Mill Wright •Camera Pass - Schedule Install date - Provide Replacement Parts List & Pricing Edge Control Systems Installed Base - 200+ edge control installations world wide - Installations on a wide variety of paper types Edge Control Systems Thank you!.
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