Molded Fibre Pulp Dilution for Consistent Product Properties
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Solution Overview
Problem
There is a need for consistent production of high-quality molded fibre products that meet the high requirements for properties such as stiffness and hydrophobicity, which existing methods struggle to achieve.
Innovation Solution
A multistep dilution process is employed to control the consistency of fibre suspensions at different stages, allowing for precise control of the final consistency and quality of molded fibre products, including multiple dilution steps and the use of chemical additives like alkyl ketene dimer (AKD) to enhance properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single-step dilution process is used, then the production process is simple, but the consistency control of fibre suspension is poor leading to variable product quality
Solution Approach 1:
The dilution process is divided into multiple sequential steps with intermediate storage tanks, allowing consistency to be controlled and adjusted at each stage rather than in a single step, thereby achieving better overall consistency control while managing process complexity
Solution Approach 2:
The fibre suspension is prepared and stored in intermediate tanks before final formation, allowing preliminary consistency adjustments and stabilization to occur before the actual molding process, ensuring consistent quality in the final product
2Manufacturing precision
If chemical additives are added to improve product properties, then the quality of molded fibre product improves, but the production cost increases
Solution Approach 1:
The consistency of fibre suspension is precisely controlled through multistep dilution to optimal ranges for chemical additive performance, allowing additives to work more efficiently at lower concentrations while still achieving desired product properties
Solution Approach 2:
The process utilizes white water from the forming step and washing water from the pulper for dilution purposes, reducing the need for fresh water and chemical additives while maintaining consistent consistency control throughout the production process
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method ensures consistent production of high-quality molded fibre products by maintaining precise consistency and enabling optimal performance of chemical additives, resulting in controlled properties and reduced waste.
Implementation Method 1
The fibres are present in a suspension at different consistencies during different steps by the use of a multistep dilution process. The method enables making small consistency changes by first reducing the consistency of the fibre suspension to 5-7 wt. % and then in several steps reducing it to the final 0.1-0.7 wt. %.
Implementation Method 2
Preferably, at least one chemical additive such as alkyl ketene dimer (AKD), is added to the furnish in the circulation tank.
Data Source
AI summary
The present disclosure relates to a method of producing a molded fibre product, comprising the steps of:a) converting a dry pulp to a wet pulp having a consistency of 2-4 wt. %;b) diluting the wet pulp to obtain a diluted pulp having a consistency of 0.8-1.9 wt. %;c) storing the diluted pulp in a machine tank;d) diluting the diluted pulp from the machine tank to obtain a furnish having a consistency of 0.1-0.7 wt. %;e) storing the furnish in a circulation tank;f) feeding the furnish from the circulation tank to a forming tank; andg) forming the molded fibre product from the furnish in the forming tank.