Forming and Water Removal in Wetlaid Fiberglass Mat Production with Kyle Neal
In a recent interview, Kyle Neal outlined how the optimization of forming and water removal in the wetlaid fiberglass mat production process can drive quality, efficiency, and cost savings for manufacturers. Kyle, technical manager of forming products for Kadant Solutions, has over 15 years of experience in the paper industry and a degree in Paper Process Engineering from Western Michigan University. Kyle has dedicated his career to advancing forming, water removal, and vacuum system technologies. His expertise spans both traditional paper machines and other industries with similar processes, such as wetlaid fiberglass mat production.
V: Kyle, can you explain what forming is in the wetlaid fiberglass mat production process?
K: Absolutely. Forming is an important stage in the wetlaid fiberglass mat production process where the goal is to maximize and control water removal to support and optimize the mat’s structure, quality, and production across the machine. During the forming process, the fiber suspension is deposited onto the wire, and water is removed to begin creating the mat.
V: Why are forming and water removal so important in the wetlaid fiberglass mat production process?
K: The wetlaid fiberglass mat forming process is fundamental to product quality and machine efficiency. It’s all about creating the right sheet structure, fiber orientation, and uniformity across a wide range of grades, each with different fiber lengths and drainage characteristics. At the same time, we need to remove enough water to support production requirements. When the forming process is optimized, we can reduce the use of water, drive and vacuum energy, and chemistry. That means lower costs and improved sustainability.
V: What are the key steps in the forming process for wetlaid fiberglass mat production, and how do they impact water removal?
K: The forming process starts with dispersion, where the goal is to keep fibers apart to prevent entanglement. Next is the approach flow and headbox, which delivers a uniform suspension to the wire. Finally, in the former, we focus on maximizing and controlling water removal to support mat structure and quality. Each step has specific parameters that need to be managed to ensure optimal drainage and product consistency.
V: What are some best practices for controlling water removal throughout the former?
K: Water removal should match the geometry of the headbox to maintain desired stock velocities. Too much water removal can reduce stock velocity, while too little can lead to higher velocities – controlling stock velocities is key to controlling tensile ratios. Lastly on the former, it’s important to gradually increase vacuum levels as resistance to drainage increases through the former in order to keep maintain adequate drainage efficiencies and maximize overall drainage capacity.
V: Can you share some optimization tips for forming equipment design in wetlaid fiberglass mat processes?
K: Reducing slot area or widths early on in the process can provide more gradual control of water removal, while increasing them can boost drainage capacity if needed. The design of vacuum box covers, including slot width adjustment, affects dwell time and airflow density to maximize water removal efficiency in higher consistency areas. Different cover arrangements and materials like UHMW poly or ceramic alternatives offer flexibility and durability. Built-in adjustability, such as blanking strips or offset mounting slots, allows operators to fine-tune drainage capacity and improve ergonomics, reducing maintenance time and effort.
V: What are the main benefits wetlaid fiberglass mat producers can expect from optimizing forming and water removal?
K: Optimizing forming and water removal leads to quality and production improvement, and chemistry and energy reduction. For example, increasing sheet solids into the saturator can reduce dryer energy consumption and allow for higher machine speeds. Improved drainage capacity can remove production bottlenecks and allows for operation at lower consistencies. This will reduce fiber interaction and can lower the need for dispersion chemistry. Ultimately, these improvements drive cost savings and support sustainable production.
V: Where does Kadant Solutions fit into the forming and water removal process for wetlaid fiberglass mat production?
K: Kadant has a long history of forming expertise, and we apply that knowledge to help our customers achieve their production, quality, and cost-saving goals. When it comes to water removal, Kadant’s vacuum boxes and covers are engineered for precise control allowing operators to adjust slot areas and vacuum levels to match the needs of different fiber lengths and grades.
We offer multiple grades of polyethylene covers for durability and drive optimization, as well as ceramic wear surfaces. Our modular cover designs and built-in adjustability features, like blanking strips and offset mounting slots, make it easier to fine-tune drainage capacity and adapt to changing production requirements. These innovations not only improve ergonomics and reduce maintenance time but also support higher machine speeds and better product quality.
