Papermaking

PDC’s pilot paper machine is available for raw material and process operation studies. The paper machine may also be used to evaluate equipment components. Steady state is reached in less than thirty minutes, allowing multiple trials in a single day.

The PDC’s pilot paper machine is capable of several processes, including complete equipment analysis, raw material studies, and process operation studies.

student looking at the pilot paper machine

Specifications

  • Basis weight range: 25-220 g/m2
  • Average production rate: 1 lb/min
  • 10-100 fpm
  • 13″ trim

Equipment List

  • 6-slice dilution headbox with Holey roll
  • Close white water system with on-line suspended solids and charge monitoring for highly efficient wet-end chemical studies
  • Two wet press nips with metal and/or composition rolls
  • Upgraded size press
  • Versatile size press coating supply system
  • In-line, multi-nip steel-steel calendar stack
  • High precision drive system
  • On-line continuous monitoring of basis weight, moisture, caliper, and ash
  • Unwind stand to enable size press/coating experiments using customer supplied base paper rolls

Equipment:

  • Two felted press nips with a separate embossing nip for specialty applications
  • Size press
  • Quick change-over size press coating supply system
  • In-line steel-steel nip calendar stack
  • High precision drive system
  • Honeywell Experion MX scanner with on-line monitoring of basis weight, moisture, caliper, and ash, in both the machine and cross-machine direction
paper machine's size press

A size press is an option in the operation of the pilot paper machine. This sophisticated piece of equipment allows for the addition of surface sizing, as well as a light coating on the base sheet. Our upgraded size press allows for a wide range of coating and surface treatments to be applied, such as silicone and barrier coatings, and therefore, expand the types of high-value, specialty paper and composite prototypes that can be produced.

Coating

The PDC routinely works with clients to improve product properties and lower costs by formulating and applying coatings to their products. Coating a thin layer of material on the surface of paper, film, foil, or composites is a very effective method of adding functionality and value to a product. Printing papers, paper cups, grease-resistant food packaging, and high-strength composites all benefit from quality coatings. For applying coatings, the PDC has a bench drawdown coater as well as a Faustel Labmaster coater.

Faustel Labmaster Coater

Coating application is one of the most important steps in making paper, foil and other materials, and the PDC is now able to coat commercially made basepapers or specialty basepapers produced on our pilot paper machine using a variety of methods. The Faustel Labmaster coater offers a versatile range of coating applications for papers, films, foils, non-wovens, and specialized composite materials.

The pilot coater has flexible, three-roll coating configurations for:

  • Direct gravure
  • Offset gravure
  • Smooth roll direct
  • Offset smooth roll
  • Kiss coating

Some of the pilot coater’s other features include:

  • Trailing blade or rod coating
  • Web processing at up to 12 inches in width
  • Speeds up to 100 fpm
  • Non-contact, hot air drying
  • Fully equipped laminating station

Calendering

Calendering improves printing properties, particularly roughness and gloss. The values attained depend on the speed, pressure, and temperature of calendering, the properties of the base sheet, the average moisture content, and the composition of the coating. The options available for calendering include:

  • On-line steel calendar stack before the reel of the paper machine
  • Off-line heated, soft-nip calender stack

Capabilities

  • Evaluation of base stock/coating interactions
  • Development and evaluation of innovative barrier coatings
  • Evaluation of coating additives, including bio-based polymers
  • Determination of coating structure/property relationships
  • Determination of physical-chemical interactions between paper surface and inks
  • Evaluation of variables affecting gloss development following calendering
  • Off-line rewinding/slitter
  • Off-line sheeter
  • Off-line guillotine

To begin working with us, visit our Working with the PDC page.