Progress in foam forming technology

Kiiskinen, Harri; Salminen, Kristian; Lappalainen, Timo; Asikainen, Jaakko; Keränen, Janne; Hellén, Erkki

doi:10.32964/tj18.8.499

Cited by 9 publications

(12 citation statements)

References 31 publications

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“…[76] After a few decades in late 2000s, interest in foam-forming technology was raised again, and several pilot-scale studies have been published during the last 10 years. [4][5][6]18,45,[106][107][108]…”

Section: Manufacturing Process Operationsmentioning

confidence: 99%

“…They reported a 10% bulk increase in middleply at the equal internal strength level. Kiiskinen et al [6] reported pilot-scale results for a single-ply board from CTMP pulp. In their study, the increase in bulk of the foam-formed board was 18-20% higher compared to water-laid reverence at a given press solids content level (Figure 33).…”

Section: Packaging Boardsmentioning

confidence: 99%

“…Three different foam density levels, 400, 500, and 650 kg/m 3 , were tested. [6] layer purity can be achieved and this might also lead to raw-material savings.…”

Section: Packaging Boardsmentioning

confidence: 99%

“…Foam forming is a process that enables the making of a variety of fiber products, [1] ranging from paper [2][3][4][5][6] and lightweight packaging [7] to nonwoven fabrics [8][9][10] and insulation, [11][12][13][14][15] filtering [13,16,17] and construction materials. In this method, the advantages of traditional water-forming technology are combined with the improved ability of handling very different kinds of raw materials such as long fibers [10,18] or particles with varied densities.…”

Section: Introductionmentioning

confidence: 99%

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Foam forming of fiber products: a review

Hjelt

Ketoja

Kiiskinen

et al. 2021

Journal of Dispersion Science and Technology

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Aqueous foam can be used as a transfer medium to form lightweight materials from natural and man-made fibers together with other types of raw materials. This review discusses mechanisms that underlie the forming process and thus influence physical properties of formed fiber networks such as microporous structure, strength behavior, and transport properties. Homogeneous fiber materials can be formed from versatile raw materials, which makes the technology suitable for a vast range of product applications. An intriguing feature of the method is that the wet foam characteristics provide an additional tool to tailor the performance of the dried material. Understanding foam rheology and how that is affected by added fibers is important in developing the forming process. We introduce both fundamental foam properties and practical forming methods, and show how the material properties are affected by the foam-fiber interaction. The basic features of an industrial production process are also described. The potential material properties are compared against key requirements in typical product applications.

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Section: Manufacturing Process Operationsmentioning

confidence: 99%

Section: Packaging Boardsmentioning

confidence: 99%

“…Three different foam density levels, 400, 500, and 650 kg/m 3 , were tested. [6] layer purity can be achieved and this might also lead to raw-material savings.…”

Section: Packaging Boardsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Foam forming of fiber products: a review

Hjelt

Ketoja

Kiiskinen

et al. 2021

Journal of Dispersion Science and Technology

Self Cite

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“…How valuable would it be if an existing production line could be used to produce higher value or even entirely new products? To respond to this challenge, foam forming technology has attracted much attention during the past few years (Lehmonen et al 2013;Kinnunen-Raudaskoski 2017;Kiiskinen et al 2019;Lehmonen et al 2019). Foam forming utilizes small air bubbles (average bubble radius < 100 µm) containing aqueous foam instead of pure water as a process fluid and flowing medium.…”

Section: Introductionmentioning

confidence: 99%

Process simulation-based evaluation of design and operational implications of water-laid paper machine conversion to foam technology

Sorsamäki

Koponen

Hytönen

2021

BioRes

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Foam forming technology has attracted much attention during the past few years in the paper industry. Its advantages compared to conventional water forming are a new product portfolio and increased process efficiency. To support the paper industry in pushing foam forming technology forward, process simulation is needed to provide supporting data for strategic decision-making and as a basis for equipment dimensioning. This study examined the conversion of an existing wallpaper machine from water to foam forming technology using process simulation. To determine the required process configuration and parameter changes in the existing process, both published and unpublished data on the foam forming process were collected. This paper also describes modeling of the foam phase in the selected simulation software. The suitability of existing paper process equipment for foam was analyzed. Simulations revealed that undisturbed operation with foam requires some equipment modifications and re-arrangements in water circuits. With foam forming, the water balance in both short and long circulation changes remarkably compared to conventional water forming, leading to a large increase in the long circulation volume flows.

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Air‐laid and foam‐laid nonwoven composites: The effect of carrier medium on mechanical properties

Paunonen,

Keränen,

Kamppuri

2024

J of Applied Polymer Sci

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Thermoplastic nonwoven composites were produced with the air‐laying and foam‐forming processes from cellulosic and plastic fibers. The two raw material combinations were (1) PP/PE (fiber length 3 mm), PP/PE (12 mm), fluff pulp fibers (2 mm) and (2) PP/PE (3 mm), fluff pulp fibers, viscose (10 mm). After forming, the fibrous sheets (400 gsm) were bonded with heat pressing (145°C). The effect of the carrier medium, air or aqueous foam, on the tensile and impact properties and sheet structure was explored. The air‐laids differed from the foam‐laids by sheet anisotropy, density, and the lack of an additional bonding regime between wood fibers due to the dry forming process. The PP/PE bonding fibers gave the air‐laids a good capacity to elongate compared to the foam‐laids. The advantage was lost when nonbonding viscose was added. The impact strength was dependent on the PP/PE dosage and the sheet density, rather than the moisture‐induced bonding between wood fibers. The changing long/short fiber ratios caused gradual shifts in sheet properties, usually a reduction in a mechanical property as the share of short fiber increased in the mix. Economic analysis revealed that increasing fluff content can reduce raw material costs, providing a possibility for cost optimization in total production costs.

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Progress in foam forming technology

Cited by 9 publications

References 31 publications

Foam forming of fiber products: a review

Foam forming of fiber products: a review

Process simulation-based evaluation of design and operational implications of water-laid paper machine conversion to foam technology

Air‐laid and foam‐laid nonwoven composites: The effect of carrier medium on mechanical properties

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