Ceramic Tip Creping Blade Exceeds Tissue Manufacturer’s Expectations

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 that affects the tissue creping process.

Tissue manufacturing takes less than two seconds, from when the sheet is first formed until you have a jumbo roll of tissue. 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 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.

Results
After running the CeraEdge creping blades the production team realized the following results:

• 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

CeraEdge Creping Blades Manufactured in the USA

In 2015, Kadant Solutions expanded its manufacturing capacity for the CeraEdge™ creping blades product line in the U.S.  The facility, located in Auburn, Mass. just outside of Boston, allows for a quicker turnaround time compared to bringing the product in from our European facility. Being able to manufacture the CeraEdge blades in the U.S. allows us to quickly and efficiently serve our customers. This means on-time deliveries and easier inventory management.

CeraEdge LThe CeraEdge creping blade line utilizes a thermal spray technology to offer a unique ceramic-tipped blade that provides tissue producers with excellent creping performance in terms of operating life and tissue properties.

The CeraEdge L creping blade is designed for applications seeking extended blade life resulting in high productivity and maximum asset utilization. For tissue producers seeking high tissue softness, the CeraEdge S creping blade is CeraEdge Srecommended for relatively dirty furnish due to its insensitivity to particles and contaminants. The thermal stability of both products reduces blade buckling, twisting, and warping compared to other products in the marketplace.

The CeraEdge creping blades fit nicely in Kadant’s product portfolio for tissue producers, which includes Yankee doctor systems and holders, spray booms, suction pressure roll doctors, steam and condensate equipment, and technical service. This puts Kadant in a unique position to become a valuable partner in the tissue-making process and not just a blade supplier.