Energy Saving Blades: Enhancing Efficiency and Reducing Costs

Since the early 1980s, Kadant has been at the forefront of producing doctor blades containing carbon fiber. These low friction blades are designed to reduce energy consumption by decreasing drag, which in turn provides numerous benefits to paper manufacturers.

One of the key advantages of using low friction carbon blades is their longer lifespan, lasting up to four times longer than traditional blades. This increased durability leads to higher production rates and reduced variances in quality parameters. Additionally, the use of these blades results in reduced chemical usage and significant energy savings. For example, with an 8% reduction in Yankee drive energy consumption.

In addition to the selection of carbon-containing blade materials, there are other ways to lower energy consumption. The direct effect of blade pressure and friction on energy consumption is a critical consideration. Excessive doctor load can increase drive amps, particularly in dryer sections with multiple doctors in one drive group. Proper doctoring and maintaining clean dryer surfaces can improve thermal transfer rates and decrease steam consumption. A dirty dryer surface acts as a thermal resistance, decreasing contact drying rates and requiring additional steam to overcome the buildup on the drying cylinder. By eliminating this additional energy usage, manufacturers can achieve more efficient operations.

To optimize energy savings, blades should be loaded with just enough pressure to effectively clean the roll. Any additional force is wasted energy that increases the energy required to run the cylinder or roll, and prematurely wears the blade.

Implementing best practices for low energy doctoring is essential. These practices include using the lowest pressure possible compatible with the desired results, utilizing flexible blades, employing self-conforming holders such as the UniClean-S™, lubricating when possible, keeping dryer surfaces clean, and using low energy blades.

By following these guidelines and utilizing Kadant's energy-saving blades, paper manufacturers can achieve significant energy savings, improve production efficiency, and reduce operational costs.

Carbon Fiber, Low Friction Energy Saving Blades

SynTek™ Plus, SynTek C, nSlip™, and CarboTek™ 500 doctor blades

Four Considerations When Choosing a Doctor Blade

When choosing a doctor blade, there are several important factors to consider ensuring optimal performance and doctor blade efficiency.

1. Blade Load 
   The blade should be loaded with just enough pressure to effectively clean the roll. Any additional force is wasted energy and can prematurely wear the blade itself. Always use the lowest pressure possible that is compatible with the desired results.

2. Blade Construction
   A doctor blade containing carbon can provide lubrication, while a blade containing glass can be more effective for cleaning. It's important to choose the right material based on your specific needs and applications.

3. Product Application
   Doctor blades can be used for various purposes such as dewatering or conditioning. The specific application will influence the type of blade chosen.

4. Mill Objectives
   The overall goal is a clean roll, which can be achieved through a combination of blade material selection, holder choice, and loading. Keeping a drying cylinder clean improves heat transfer and uses less energy. By carefully considering these factors, you can select the most suitable doctor blade for your needs, ensuring efficient and effective performance.