A METHOD FOR PRODUCING A CELLULOSE PRODUCT AND A CELLULOSE PRODUCT

Abstract

A method for producing a cellulose product from an air-formed cellulose blank structure includes the steps of providing a cellulose-based material to a mill, milling the cellulose-based material, and providing an air-formed cellulose blank structure, wherein the cellulose blank structure is air-formed from cellulose fibres.

Claims

1. A method for forming an air-formed cellulose blank structure for producing a cellulose product, wherein the method comprises: providing a flow of cellulose-based material to a mill, defibrating the cellulose-based material in the mill into cellulose fibres, providing an air-formed cellulose blank structure, wherein the cellulose blank structure is air-formed from the cellulose fibres, wherein the step of air-forming comprises the step of feeding the cellulose fibres to a first opening in a forming hood, wherein the cellulose fibres are directed onto a first side of a conveyer belt by the forming hood via a second opening in the forming hood, wherein a suction box is arranged in connection to a second side of the conveyer belt opposite the second opening of the forming hood, wherein the suction box comprises a fan that is connected to the suction box that creates an under-pressure generating a negative pressure gradient between the first side and the second side of the conveyer belt via through openings in the conveyer belt for forming the cellulose blank structure from the cellulose fibres directed onto the first side of the conveyer belt, providing the cellulose blank structure to a forming mould for forming the cellulose blank structure into a three dimensional cellulose product, intermittently operating the forming mould to apply a forming pressure onto the cellulose blank structure, and synchronizing the conveyer belt to intermittently form the cellulose blank structure simultaneously to the intermittent operation of the forming mould or between two intermittent operations of the forming mould.

2. The method according to claim 1, wherein the step of providing the cellulose blank structure to a forming mould comprises the step of feeding the cellulose blank structure essentially vertically.

3. The method according to claim 2, wherein the step of intermittently operating the forming mould to apply a forming pressure onto the cellulose blank structure, comprises the step of operating the forming mould in a horizontal pressing stroke.

4. The method according to claim 1, wherein the method comprises a step of cutting out the cellulose product from the cellulose blank structure in and/or after the forming mould, thereby forming a residual cellulose fibre structure of the remaining cellulose blank structure, and feeding the material of the residual cellulose fibre structure to the mill as a complement to the flow of cellulose-based material.

5. The method according to claim 1, wherein the method comprises the step of providing a first tissue layer onto one side of the cellulose blank structure, wherein the first tissue layer comprises a barrier chemistry composition.

6. The method according to claim 5, wherein the method comprises the step of providing a second tissue layer to one side of the cellulose blank structure, wherein the second tissue layer comprises a barrier chemistry composition.

7. The method according to claim 5, wherein the barrier chemistry composition is provided to the first and/or second tissue layer during production and/or the step of providing the barrier chemistry composition to the first and/or second tissue layer by providing the barrier chemistry composition before production.

8. The method according to claim 1, wherein the method comprises the step of step of providing a barrier chemistry composition to the cellulose-based material before production and/or in production.

9. The method according to claim 1, wherein the step of air-forming comprises the step of feeding the conveyer belt vertically such that the fibres are fed to the conveyer belt horizontally.

10. A cellulose product machine configured to form an air-formed cellulose blank structure for producing a cellulose product, wherein the machine comprises a first transport unit, a mill, a forming hood, a conveyer belt, a suction box, a second transport unit and a forming mould, wherein the first transport unit is configured to: provide a flow of cellulose-based material to the mill, wherein the mill is configured to defibrate the cellulose-based material into cellulose fibres, wherein the forming hood comprises a first opening in fluid communication with the mill and a second opening in fluid communication with a first side of the conveyer belt, wherein the suction box is arranged in connection to a second side of the conveyer belt opposite the second opening of the forming hood, wherein the suction box comprises a fan that is connected to the suction box that creates an under-pressure generating a negative pressure gradient between the first side and the second side of the conveyer belt via through openings in the conveyer belt, wherein the forming hood is configured to provide an air-formed cellulose blank structure onto the conveyer belt, wherein the cellulose blank structure is air-formed from the cellulose fibres by the mill being configured to feed the cellulose fibres to the first opening in the forming hood, wherein the forming hood is configured to direct the cellulose fibres onto the first side of the conveyer belt via the second opening in the forming hood, wherein the second transport unit is configured to provide the cellulose blank structure to the forming mould for forming the cellulose blank structure into a three dimensional cellulose product, wherein the forming mould is configured to intermittently operating the forming mould to apply a forming pressure onto the cellulose blank structure, wherein the conveyer belt is synchronized with the forming mould to intermittently form the cellulose blank structure simultaneously to the intermittent forming pressure of the forming mould or between two intermittent operations of the forming mould.

11. The cellulose product machine according to claim 10, wherein the second transport unit is configured to provide the cellulose blank structure to the forming mould vertically.

12. The cellulose product machine according to claim 10, wherein the forming mould is configured to operate in a horizontal pressing stroke.

13. The cellulose product machine according to claim 10, wherein the conveyer belt is configured to run vertically such that the fibres are fed to the conveyer belt horizontally.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0061] The disclosure regarding the machine hereinafter called Scala will be described in detail in the following, with reference to the attached drawings, in which

[0062] FIG. 1 schematically shows, Scala with covers from Front/Left,

[0063] FIG. 2 schematically shows, Scala with covers from Back/Right,

[0064] FIG. 3 schematically shows, Product Plundering Alternatives,

[0065] FIG. 4a schematically shows, Main measurement of a top view,

[0066] FIG. 4b schematically shows, Main measurement of a front view,

[0067] FIG. 4c schematically shows, Main measurement of a side view,

[0068] FIG. 5 schematically shows, High-Way Product Examples,

[0069] FIG. 6 schematically shows, Machine Consumables Supply & Load,

[0070] FIG. 7 schematically shows, Operator's Interfaces in Running Mode,

[0071] FIG. 8 schematically shows, Lids, doors and tiltable items,

[0072] FIG. 9 schematically shows, Access openings seen from front,

[0073] FIG. 10 schematically shows, Access openings seen from back,

[0074] FIG. 11 schematically shows, Machine Supply Inlets,

[0075] FIG. 12a schematically shows, Main Architecture with Sub-Systems

[0076] FIG. 12b schematically shows, Functional Flow Chart of FIG. 12a,

[0077] FIG. 13 schematically shows, Schematic Functional Overview with Motor Names,

[0078] FIG. 14 schematically shows, Schematic Diagram Scala Nomenclature (Examples Only),

[0079] FIG. 15 schematically shows, Physical sub-assemblies of Scala,

[0080] FIG. 16 schematically shows, Scala Sub-Systems; seen from Front View,

[0081] FIG. 17 schematically shows, Scala Sub-Systems; seen from Rear-Right View,

[0082] FIG. 18 schematically shows, Mill-to-Web (1) Sub-Units; Front-Right View,

[0083] FIG. 19 schematically shows, Mill-to-Web Sub-Units; Back-Right View,

[0084] FIG. 20a schematically shows, Saw Tooth Mill Subunit (1:2)Main Components Closed,

[0085] FIG. 20b schematically shows, Saw Tooth Mill Subunit (1:2)Main Components Opened,

[0086] FIG. 21 schematically shows, Schematic Illustration of Saw Tooth Mill,

[0087] FIG. 22 schematically shows, Web Forming Subunit-Main Components,

[0088] FIG. 23 schematically shows, Stop-and-Go Operation of Web Forming and Moulding,

[0089] FIG. 24 schematically shows, Stop-and-Go Operation of Web Forming and Moulding,

[0090] FIG. 25 schematically shows, Web Forming Subunit seen from underneath-Main Components,

[0091] FIG. 26 schematically shows, Web Forming Evenness between 9 samples in a 500500 mm web,

[0092] FIG. 27 schematically shows, Web Quality Sampling,

[0093] FIG. 28 schematically shows, Tissue Sub-System (2)Sub-Units, seen from Left-Front,

[0094] FIG. 29 schematically shows, Tissue Sub-System (2)Sub-Units, seen from Right-Back,

[0095] FIG. 30 schematically shows, Tissue Feeding Assembly,

[0096] FIG. 31 schematically shows, Tissue Feeding AssemblyExploded View,

[0097] FIG. 32 schematically shows, Manual Tissue Splicing,

[0098] FIG. 33 schematically shows, The Moulding Sub-Systemseen Front/Left,

[0099] FIG. 34 schematically shows, The Clamping Unit Main Components-seen Back Left,

[0100] FIG. 35a schematically shows, a side view of the Clamping Unit,

[0101] FIG. 35b schematically shows, Force Characteristics (empirical measured) of the Clamping unit in FIG. 35A,

[0102] FIG. 36 schematically shows, Feeder Sub-UnitWeb Feeder Shown closed,

[0103] FIG. 37 schematically shows, two Feeder Sub-Units,

[0104] FIG. 38 schematically shows, Feeder Sub-UnitWeb Feeder Shown closed,

[0105] FIG. 39 schematically shows, Feeder Roller Assembly (Exploded view),

[0106] FIG. 40 schematically shows, The Tool Sub-System in perspective with open Tools and Cut Web,

[0107] FIG. 41 schematically shows, A Typical 9-cavity Tool Sub-System setup,

[0108] FIG. 42 shows a Typical Dry Moulded Fibre Single-Use Lid Product (5:8),

[0109] FIG. 43 schematically shows, A Typical Male of a single cavity mould for Dry Moulded Fibre Lid, in cross section,

[0110] FIGS. 44a-d schematically shows, a forming cycle A-D in a 2D cross section of the Lid tool,

[0111] FIG. 44e schematically shows, a pressure diagram,

[0112] FIG. 45a schematically shows, a Multi Cavity Tool comprising nine cavities,

[0113] FIG. 45b schematically shows, an enhanced excerpt of the Multi Cavity Tool in FIG. 45a with four cavities,

[0114] FIG. 46 schematically shows, a Recycling Sub-System, seen from Front/Left,

[0115] FIG. 47a schematically shows, the Recycling Sub-System, seen from Back side,

[0116] FIG. 47b schematically shows, the Recycling Sub-System, seen from Back side,

[0117] FIG. 48 schematically shows, Scala with Covers,

[0118] FIG. 49 schematically shows, The Cover Sub-System in FIG. 48 in an Exploded view,

[0119] FIG. 50 schematically shows a Human Interface, HMI, Scala.

[0120] FIG. 51 schematically shows HMI Panel, measurements in mm.

DESCRIPTION OF EXAMPLE EMBODIMENTS

[0121] Various aspects of the disclosure will hereinafter be described in conjunction with the appended drawings to illustrate and not to limit the disclosure, wherein like designations in many cases are different for like elements, and variations of the described aspects are not restricted to the specifically shown embodiments, but are applicable on other variations of the disclosure.

[0122] The description below will refer to Scala as a collective name for a machine for producing a cellulose product according to the invention, where the machine will comprise a variety of parts that will be explained below and in connection to the drawings.

[0123] The invention relates to a method for forming an air-formed cellulose blank structure 102 for producing a cellulose product 101, which is shown in various aspects in FIGS. 1-51, wherein the method comprises the steps; [0124] providing a flow of cellulose-based material 106 to a mill 104, [0125] defibrating the cellulose-based material 106 in the mill 104 into cellulose fibres, providing an air-formed cellulose blank structure 102, [0126] wherein the cellulose blank structure 102 is air-formed from the cellulose fibres, [0127] wherein the step of air-forming comprises the step of feeding the cellulose fibres to a first opening 104a1 in a forming hood 104a, [0128] wherein the cellulose fibres are directed onto a first side 112 of a conveyer belt 111 by the forming hood 104a via a second opening 104a2 in the forming hood 104a, [0129] wherein a suction box 104b is arranged in connection to a second side 112b of the conveyer belt 111 opposite the second opening 104a2 of the forming hood 104a, wherein the suction box 104b comprises a fan 104b1 that is connected to the suction box 104b that creates an under-pressure generating a negative pressure gradient between the first side 112 and the second side 112b of the conveyer belt 111 via through openings in the conveyer belt 111 for forming the cellulose blank structure 102 from the cellulose fibres directed onto the first side 112 of the conveyer belt 111, [0130] providing the cellulose blank structure 102 to a forming mould 105 (also called clamping unit) for forming the cellulose blank structure 102 into a three dimensional cellulose product 101, [0131] intermittently operating the forming mould 105 to apply a forming pressure onto the cellulose blank structure 102, [0132] synchronizing the conveyer belt 111 to intermittently form the cellulose blank structure 102 simultaneously to the intermittent operation of the forming mould 105.

[0133] One advantage with the method is that the synchronization allows for a compact machine with high control of all process steps. In a stationary mode, the conveyor belt is arranged in a standstill state such that the cellulose blank structure is formed on an at least partly non-moving conveyor belt. Here, it should be understood that the cellulose blank structure can be formed onto the conveyer belt only when the conveyer belt is in a standstill, or alternatively is formed when the conveyer belt moves into the standstill and during the standstill, or alternatively is formed during the standstill and when the conveyer belt moves from the standstill, or alternatively is formed when the conveyer belt moves into the standstill and during the standstill and when the conveyer belt moves from the standstill. In yet another example, the cellulose blank structure can be formed onto the conveyer belt only when the conveyer belt is moving, i.e. synchronized with the forming mould to allow forming of the cellulose blank structure between two pressing operations. The duration of the standstill state is synchronized with the duration of the pressing operation such that the standstill state is occurring during the pressing operation. The conveyor belt may be arranged in the standstill state at any time during pressing operation, and the time duration of the standstill state may be only a part of the time duration of the pressing operation, or alternatively the full pressing operation. I.e., the conveyor belt is synchronized to intermittently be in a standstill state during parts of or the whole of the application of a forming pressure onto the cellulose blank structure in the forming mould. The conveyor belt is advantageously an air permeable forming wire configured in a position close to the suction box on one side and the web forming on the opposite side. The suction box creates an under-pressure on the forming wire that creates an airstream in a direction towards the suction box, such that that the fibres are formed into the cellulose blank structure onto the forming wire.

[0134] According to one advantageous example, the step of providing the cellulose blank structure 102 to a forming mould 105 comprises the step of feeding the cellulose blank structure 102 essentially vertically.

[0135] This has the advantage of a small and compact machine.

[0136] According to one advantageous example embodiment, the step of intermittently operating the forming mould 105 to apply a forming pressure onto the cellulose blank structure 102, comprises the step of operating the forming mould 105 in a horizontal pressing stroke.

[0137] This has the advantage of a small and compact machine, especially together with vertically fed cellulose blank structure.

[0138] According to one advantageous example embodiment, the method comprises a step of cutting out the cellulose product 101 from the cellulose blank structure 102 in and/or after the forming mould 105, thereby forming a residual cellulose fibre structure 110 of the remaining cellulose blank structure 102, and feeding the material of the residual cellulose fibre structure 110 to the mill 104 as a complement to the flow of cellulose-based material 106.

[0139] According to one example embodiment, the method comprises the step of providing a first tissue layer 106a onto one side 102a of the cellulose blank structure 102, wherein the first tissue layer 106a comprises a barrier chemistry composition.

[0140] According to one example embodiment, the method comprises the step of providing a second tissue layer 106b to one side 102b of the cellulose blank structure 102, wherein the second tissue layer 106b comprises a barrier chemistry composition.

[0141] According to one example embodiment, the barrier chemistry composition is provided to the first and/or second tissue layer during production and/or the step of providing the barrier chemistry composition to the first and/or second tissue layer by providing the barrier chemistry composition before production.

[0142] According to one example embodiment, the method comprises the step of step of providing a barrier chemistry composition to the cellulose-based material 106 before production and/or in production.

[0143] According to one example embodiment, the step of air-forming comprises the step of feeding the conveyer belt 111 vertically such that the fibres are fed to the conveyer belt 111 horizontally.

[0144] The invention further relates to a cellulose product 101 machine 100, also called Scala in the description, which is shown in various aspects in FIGS. 1-51. The Machine 100 is configured for performing the method according to any one of the preceding claims, wherein the machine 100 is configured to form an air-formed cellulose blank structure 102 for producing the cellulose product 101, wherein the machine comprises a first transport unit 103, a mill 104, a forming hood 104a, a conveyer belt 111, a suction box 104b, a second transport unit 109 and a forming mould 105, wherein the first transport unit 103 is configured to [0145] provide a flow of cellulose-based material 106 to the mill 104a, wherein the mill 104a is configured to defibrate the cellulose-based material 106 into cellulose fibres, [0146] wherein the forming hood 104a comprises a first opening 104a1 in fluid communication with and in connection to the mill 104a and a second opening 104a2 in fluid communication with and in connection to a first side 112 of the conveyer belt 111, [0147] wherein the suction box 104b is arranged in connection to a second side 112b of the conveyer belt 111 opposite the second opening 104a2 of the forming hood 104a, wherein the suction box 104b comprises a fan 104b1 that is connected to the suction box 104b that creates an under-pressure generating a negative pressure gradient between the first side 112 and the second side 112b of the conveyer belt 111 via through openings in the conveyer belt 111, wherein the forming hood 104a is configured to provide an air-formed cellulose blank structure 102 onto the conveyer belt 111, [0148] wherein the cellulose blank structure 102 is air-formed from the cellulose fibres by the mill 104 being configured to feed the cellulose fibres to the first opening 104a1 in the forming hood 104a, [0149] wherein the forming hood 104a is configured to direct the cellulose fibres onto the first side 112 of the conveyer belt 111 via the second opening 104a2 in the forming hood 104a, [0150] wherein the second transport unit 109 is configured to provide the cellulose blank structure 102 to the forming mould 105, also called clamping unit, for forming the cellulose blank structure 102 into a three dimensional cellulose product 101, [0151] wherein the forming mould 105 is configured to intermittently operating the forming mould to apply a forming pressure onto the cellulose blank structure 102, [0152] wherein the conveyer belt 111 is synchronized with the forming mould 105 to intermittently form the cellulose blank structure 102 simultaneously to the intermittent forming pressure of the forming mould 105.

[0153] In a stationary mode, the conveyor belt is arranged in a standstill state such that the cellulose blank structure is formed on an at least partly non-moving conveyor belt. Here, it should be understood that the cellulose blank structure can be formed onto the conveyer belt only when the conveyer belt is in a standstill, or alternatively is formed when the conveyer belt moves into the standstill and during the standstill, or alternatively is formed during the standstill and when the conveyer belt moves from the standstill, or alternatively is formed when the conveyer belt moves into the standstill and during the standstill and when the conveyer belt moves from the standstill. In yet another example, the cellulose blank structure can be formed onto the conveyer belt only when the conveyer belt is moving, i.e. synchronized with the forming mould to allow forming of the cellulose blank structure between two pressing operations. The duration of the standstill state is synchronized with the duration of the pressing operation such that the standstill state is occurring during the pressing operation. The conveyor belt may be arranged in the standstill state at any time during pressing operation, and the time duration of the standstill state may be only a part of the time duration of the pressing operation, or alternatively the full pressing operation. I.e., the conveyor belt is synchronized to intermittently be in a standstill state during parts of or the whole of the application of a forming pressure onto the cellulose blank structure in the forming mould. The conveyor belt is advantageously an air permeable forming wire configured in a position close to the suction box on one side and the web forming on the opposite side. The suction box creates an under-pressure on the forming wire that creates an airstream in a direction towards the suction box, such that that the fibres are formed into the cellulose blank structure onto the forming wire.

[0154] According to one example embodiment, the second transport unit 109 is configured to provide the cellulose blank structure 102 to the forming mould vertically.

[0155] According to one example embodiment, the forming mould 105 is configured to operate in a horizontal pressing stroke.

[0156] According to one example embodiment, the cellulose product 101 machine according to any one of the preceding claims 10-12, wherein the conveyer belt 111 is configured to run vertically such that the fibres are fed to the conveyer belt 111 horizontally.

[0157] The above will be further described in connection to FIGS. 1-51 with also other designations than above. The designations are shown within brackets, and in tables as positions and items for clear references.

TABLE OF CONTENT

[0158] 1.0 MACHINE MAIN DESCRIPTION [0159] 1.1 Machine Main Data [0160] 1.2 Machine Supply Interface [0161] 1.3 Human Interface (HMI) [0162] 1.4 Maintenance & Service Access [0163] 2.0 MACHINE FUNCTIONAL DESCRIPTION [0164] 2.1 MILL-TO-WEB SUB-SYSTEM [0165] 2.1.1 SAW TOOTH SUB-UNIT [0166] 2.1.2 WEB FORMING SUB-UNIT [0167] 2.1.3 SUB-SYSTEM FUNCTIONAL REQUIREMENT SPECIFICATION [0168] 2.2 TISSUE SUB-SYSTEM [0169] 2.2.1 SUB-SYSTEM FUNCTIONAL REQUIREMENT SPECIFICATION [0170] 2.3 MOLDING SUB-SYSTEM [0171] 2.3.1 CLAMPING SUB-UNIT [0172] 2.3.2 FEEDER SUB-UNIT [0173] 2.3.3 TOOL SUB-UNIT [0174] 2.3.4 SUB-SYSTEM FUNCTIONAL REQUIREMENT SPECIFICATION [0175] 2.4 RECYCLING SUB-SYSTEM [0176] 2.4.1 SUB-SYSTEM FUNCTIONAL REQUIREMENT SPECIFICATION [0177] 2.5 COVER SUB-SYSTEM [0178] 3.0 HUMAN INTERFACE (HMI) (to be specified in later issues) [0179] APPENDIX A: DATA SPECIFICATION MOTORS

1.0 Machine Main Description

[0180] FIG. 1 schematically shows Scala with covers from Front/Left Scala is loaded with pulp and tissue as shown in FIGS. 1 & 2. Pulp Roll width 500 mm dia. 1.2m. Splicing is manually done by the rolls.

[0181] FIG. 2 schematically shows Scala with covers from Back/Right

[0182] Plundering is performed in similar way as in an IMM, see FIG. 3 [0183] Random fall Out-Let A [0184] Robot Pick-Out via door Out-Let B. [0185] Robot Pick-Out Upwards C

[0186] FIG. 3 schematically shows Product Plundering Alternatives

[0187] Important functionality of the covers is to lower noise and protect operators from injuries. Access to the machinery for maintenance and service is also a functional requirement on the cover/housing design, see 1.4.

[0188] Scala should be approved and CE-marked for any sales within the European Economic Area (EEA).

1.1 Machine Main Data

[0189] FIGS. 4a-4c schematically show Main measurement; Top view FIG. 4a, Front view FIG. 4b and side view FIG. 4c.

[0190] Machine weight, excluding Pulp and tissue equals ca 10 ton

[0191] Delivered partly de-mounted in a 40 ft Shipping Container (12.22.42.6 height m)

1.2 Machine Performance Data

TABLE-US-00001 Max Pressure Force kN 2500 Min Cycle time (at product eject A) sec 3 Max Product Basis Weight (at 3 sec cycle time) gsm 1500 Max Mill Capacity (Products + Recycling) Kg/hrs. 450 Machine Internal Fibre recirculation YES Max Fibre Waste (Vacuum Fan Out-Let to Filter) % 2 Roll splicing; Pulp - every 3, 5-7 hours/roll. Manual Auto Roll Load Shift Roll Splicing; Tissue - every 10-16 hours. Manual Req. Machine Stop Max noise (with product covers) Db 80 Tool Mounting Platen; see, FIG. 5 mm 815 815 Distance between tie bars mm 555 Mould Thickness mm 200-600 Ejector Hydraulic or pneumatic Product Capacity See table 1

[0192] FIG. 5 schematically shows High-Way Product Examples, with a spoon to the left in the figure, a tray in the middle and a lid to the right.

TABLE-US-00002 TABLE 1 PRODUCT CAPACITY AT 12 MPA MOLD PRESSURE PRODUCT CYCLE SIZE WEIGHT TIME No. Products PRODUCT (cm.sup.2) GSM (g) (sec) CAVITIES Pcs./Hrs. kg/hrs. Lid dia. 78.5 600 4.7 3 9 10800 51 100 mm Spoons 16 1400 3.8 3 18 21600 82 Trays 300 700 21 3 4 4800 100 200 150 mm

1.2 Machine Supply Interface

[0193] FIG. 6 schematically shows Machine Consumables Supply & Load

TABLE-US-00003 RATED POWER (3 400 V), excl. tool heating. Max kW 120 Mill Motor x1; Max kW 30 Fan Motor x1; Max kW 37 Hydraulic Servo Motor x1; Max kW 34 Servo Motors x12; Max kW 13 Others; Max 8 Compressed Air; 8 bar - oil free l/hrs. TBD Water; Humidification; Max at dry air (RHD < 30%) l/hrs. 6 Water; Hydraulic Oil cooler; Recycled cooling media l/min 50 recommended. Max 28 deg C. RAW MATERIAL CONSUMABLES Pulp e.g., Fluff Pulp 1.2 m dia. Rolls, 450 kg hrs./roll 4-8 Tissue or Film e.g., 0.8 m dia. 29 gsm tissue hrs./roll 10

[0194] The machine ejects 5000 m.sup.3/hrs. of air (containing max 2 kg fibres/hrs when using full capacity) from the Vacuum Fan outlet. A central dust filter is needed for one or several Scala.

1.3 Human Interface (HMI)

[0195] FIG. 7 schematically shows Operator's Interfaces in Running Mode

[0196] The Operators HMI comprises: [0197] 21 TFT-LCD Touch Screen Panel with iX runtime [0198] 4 Emergency Stop Buttons [0199] Operator Alert Lamp Array on top of machine. [0200] A Smart Phone App with Push Notices with call for attention and production overview. [0201] IoTwith on-line support from Huarong and PulPac.

1.4 Maintenance & Service Access

[0202] Scala offers seven easy access openings for operators and service.

[0203] FIG. 8 schematically shows Lids, doors and tiltable items

TABLE-US-00004 O1 Front Door Sliding O2 HMI Folding HMI Mounted on Swing Arm O3 MTW Front Panel Opening Gas Springs Support O4 Upper Tissue Loading Roof Panel Gas Springs Support O5 Top Feeder Lid Gas Spring Support O6 Back Door Sliding Original Huarong O7 Electric Cabinet Tilt/Swing Opening Access to Clamping Unit Hydraulics

[0204] FIG. 9 schematically shows Access openings seen from front

[0205] FIG. 10 schematically shows Access openings seen from back

[0206] For more access at service and maintenance cover panels can be detached, see chapter 2.5 Covers Sub-System.

[0207] FIG. 11 schematically shows Machine Supply Inlets

TABLE-US-00005 AI Air In 5000 m.sup.3/hrs. (RHD 30-90%) AO Air Out To Filter; not supplied with machine; 5000 m.sup.3/hrs. PU Pulp Upper (IN) Manual Load/Automatic Splicing PL Pulp Lower (IN) Manual Load/Automatic Splicing TU Tissue Upper (IN) Manual Load & Splicing TL Tissue Lower (IN) Manual Load & Splicing EP Electric Power (IN) 120 kW (400 V 3-Phase) WI Water In Min 4 bar PI Pneumatic Air In Min 7 bar

2.0 Machine Functional Description & Specification

[0208] The operational functions, from Pulp In to finished Fibre Product, is described in the flowchart in FIGS. 12a and 12b. Six Sub Systems hosts these Functions as illustrated in FIG. 13. These Sub-Systems, Sub-Units and their Functions are described together with their functional requirement specification in this chapter.

[0209] FIGS. 12a and 12b schematically show Main Architecture with Sub-Systems, FIG. 12a and Functional Flow Chart FIG. 12b.

[0210] FIG. 13 schematically shows a Functional Overview with Motor Names

TABLE-US-00006 TABLE LIST OF MOTORS; see enclosure A for more details. Gear Motor Function Ratio kW MS1 Pulp sheet feeder 0.9 MS2 Waste web feeder (double belt in mill) 0.9 MS3 Wire Belt Drive 1.5 MS4 Web Compression 1.5 MS5 Upper Tissue Roll Drive 1.5 MS6 Lower Tissue Roll Drive 1.5 MS7 Feed Into Tool Roller 1 0.9 MS8 Feed Into Tool Roller 2 0.9 MS9 Waste Feed Out of Tool Roller 1 0.9 MS10 Waste Feed Out of Tool Roller 2 0.9 MS11 Waste Material Compression 1.5 MS12 Waste Transporter Belt 0.9 MS13 Hydraulic Pump Servo Motor 34 MA1 Mill Rotor (Frequency Converter Controlled) 30 MA2 Vacuum Fan (Frequency Converter 37 Controlled)

[0211] This document uses the following nomenclature shown in FIG. 14 when describing the Scala in a top-down structure:

[0212] FIG. 14 schematically shows a Diagram of Scala Nomenclature (Examples Only)

[0213] This Chapter of the Specification, introduces all Sub-Systems, their sub-ordinary Units, and all included Modules, controlled via the PLC.

[0214] However, Scala has five main physical sub-assemblies (except for the covers), that deviates from the Sub-Systems to some extent, i.e. the Vacuum Fan is mounted in the Tissue sub-assembly and the HMI is mounted on top of fibre supply sub-assembly in the MTW roof top cover. There is also a fibre sub assembly framework that hosts the Mill-to-Web Sub-System and the Recycling Sub-System, see FIG. 15.

[0215] In the following, this document will present and describe the Sub-Systems (i.e., without covers and without concern of sub assembly architecture).

[0216] Scala is design and manufactured as a versatile fibre moulding machine for any type of fibre product. However, the first Scalas will be sold with tooling for a specific fibre product and this document introduces the tool design as a part of the Clamping Unit Sub-System in chapter 2.3.

[0217] FIG. 15 schematically shows Physical sub-assemblies of Scala.

[0218] Scala comprises Six Sub-Systems: [0219] 1. Mill-to-Web Sub-System [0220] 2. Tissue Sub-System [0221] 3. Moulding Sub-System [0222] 4. Recycling Sub-System [0223] 5. Controller Sub-System [0224] 6. Covers Sub-System

[0225] FIG. 16 schematically shows Scala Sub-Systems; seen from Front View

[0226] FIG. 17 schematically shows Scala Sub-Systems; seen from Rear-Right View

[0227] Each of these sub-systems, with its sub-units, will be described and specified in the following.

[0228] Each Module is named using the following nomenclature:

TABLE-US-00007 CODE MODULE TYPE NOTE MS Servo Motor MA Induction Motor AH Actuator Hydraulic e.g., cylinder AP Actuator Pneumatic e.g., cylinder SI Sensor Digital SA Sensor Analogue VH Valve Hydraulic VP Valve Pneumatic UO Unit Other

2.1 Mill-to-Web Sub-System

[0229] Besides the Clamping Unit/Moulding Sub-System, the Mill-to-Web (MTW) constitutes the main sub-system of Scala. The MTW converts raw pulp (P: 1) into a fluffy loose fibre web and supply this material, as a pre-compacted web (P: 2) by and adding tissue on top and bottom in the kissing point (KP), before feed into the tool. The Saw tooth Mill (1:2) breaks up almost all hydrogen bonds in the pulp sheet (P: 1). A Vacuum Fan (1:5) draws/sucks all loose fibres through the Mill, via a Fibre Formation Hood 1:3 onto a moving wire using a vacuum suction box in the Web Forming Subunit (1:4).

[0230] FIG. 18 schematically shows Mill-to-Web (1) Sub-Units; Front-Right View Humidification is optional by spray water aerosol either in the air inlet or the fibre web (P: 2) with nozzles (not shown in fig.).

[0231] FIG. 19 schematically shows Mill-to-Web Sub-Units; Back-Right View

TABLE-US-00008 ITEM SUBUNIT NOTE 1:1 Pulp Roll Stand 1:2 Saw Tooth Mill 1:3 Fibre Hood 1:4 Web Forming Unit 1:5 Vacuum Fan Belongs physically to the Tissue Sub System (2) MS1 Pulp sheet feeder MS2 Waste web feeder (double belt in mill) Se FIG. 21 MS3 Wire Belt Drive MS4 Web Compression Roller MA1 Mill Motor MA2 Vacuum Fan Motor

2.1.1 Saw Tooth Mill Subunit

[0232] FIGS. 20a and 20b. Saw Tooth Mill Subunit (1:2)Main Components; Closed at Left, FIG. 20a, and Opened at Right, FIG. 20b.

TABLE-US-00009 ITEM MAIN COMPONENT NOTE 1:2.1 Saw Tooth Rotor Dia. 320 mm 1:2.2 Braker Bar - Waste Recycling (WR) 1:2.3 Braker Bar - Virgin Pulp (PU or PL) 1:2.4 Feeder Roller - Virgin Pulp (PU or PL) Alternated by AP1, AP2 and rotation direction of 1:2.4 1:2.5 Upper Feeder Belt - Waste Material Recycling (WR) 1:2.6 Lower Feeder Belt - Waste Material Recycling (WR) MS1 Pulp Feeder MS2 Waste web/material feeder (double belt 1:2.5 & 6) AP1 Nip Actuator Pulp Upper (PU) X2 Pneumatic Cylinder; Manually adjusted pressure regulator AP2 Nip Actuator Pulp Lower (PL) X2 Pneumatic Cylinder; Manually adjusted pressure regulator AP3 Nip Actuator Waste web belt entrance Pneumatic Cylinder; Manually X2 adjusted pressure regulator AP4 Nip Actuator Waste web belt exit X2 Pneumatic Cylinder; Manually adjusted pressure regulator SI1 Pulp Upper (PU) present sensor SI2 Pulp Lower (PL) present sensor

[0233] FIG. 21 schematically shows a Schematic Illustration of Saw Tooth Mill

2.1.2 Web Forming Subunit

[0234] FIG. 22 schematically shows a Web Forming Subunit-Main Components The Wire (1:4.1) and a rubber coated roller (1:4:3) is driven by a Servo Motor (MS3). A pivot hinged- and spring loaded, Feeder Roller (1:4.2) ensure that the Web (P: 2) follows the Wire out from the Fibre Hood into the Web Compression roller nip between (1:4.3 and 1:4.4). The degree of Web Compression is manually adjusted by the two screws (C1).

[0235] The Compression Roller (1:4.4) and the Feeder Roller (1:4.2) are both driven by Servo Motor (MS4). Both Servo Motors (MS3 and MS4) are mounted inside at the top of the Web Forming Unit underneath the wire. The Wire (1:4.1) tension is manually adjusted by the two screws (WT).

[0236] Scala has no buffer between the Mill-to-Web and the Moulding Sub-System. I.e., all Servo Motors (MS3, MS4, MS7, MS8, MS9 and MS10) operates simultaneously in a Stop-and-Go sequence. However, the Pulp and Tissue rolls has too much torque inertia to be operated at Stop-and-Go why (MS1, MS2, MS5 and MS6) operates at continuous speed. The same goes for the Recycling Sub-System (4), see Chapter 2.4.

[0237] FIGS. 23 and 24 schematically show Stop-and-Go Operation of Web Forming and Moulding.

[0238] Since booth virgin Pulp and Waste Web are feed continuous into the Mill (MA1), the fibres will be drawn to a non-moving wire most of the cycle sequence, see diagram above. I.e., one sheet, approximately 500500 mm of Web will be accumulated on the wire before feeding towards the moulding area starts.

[0239] A certain overlap between each Web Sheet will locally affect the Basis Weight GSM (gram per square meter).

[0240] The Web Forming Subunit (1:4) also holds rollers (TR) to guide the Lower Tissue path under the Suction Box and up to the Kissing Point (KP) where the Fibre Web meets the upper and lower tissue.

[0241] FIG. 25 schematically shows Web Forming Subunit seen from underneath-Main Components.

[0242] The Wire Belt (1:4.1) may drift sidewise (wandering) on the rollers, when running, why the Web Forming Unit is equipped with a simple and autonomous pneumatic feedback control system for Wire Tracking,not part of the PLC-control. A pivot pin (SI3) trailing on the edge of the Wire (1:4.6), see red ring in FIG. 25, controls a pneumatic valve via a pneumatic cylinder (AP5) moving the Tracking Roller (1:4.6) in only one end (the other fixed front end of (1:4.6) uses a spherical roll bearing) so a closed feedback regulator loop ensures that the Wire stays within +/5 mm in axial wandering.

[0243] The dotted arrows in FIG. 25. illustrates the air flow through Suction Box (1:4.7) via the Vacuum Fan 1:5 and to the outlet (AO). If several Scala Machines is installed in one facility it is recommended to install one central filter. Scala can also be equipped with an Air In-Let Manifold where air recycling can be locally arranged and installed. Scala is however sold and delivered without filter or air recycling system.

2.1.3 Mill-to-Web Sub-System Functional Requirement Specification

TABLE-US-00010 Pulp Input Max pulp reel diameter mm 1200 Pulp Reel core diameter inch 3 Max Pulp Reel width mm 508 Max Pulp Reel weight kg 350 Web Out-Put Max Basis weight (at max speed) GSM 1500 Min Basis weight GSM 400 Max Web Output capacity (Virgin + Recycled Fibres) Kg/hrs. 450 Max Web Output Capacity (at Stop-and-Go) m/min 10 Max Web Feeding Speed m/sec 0.75 Max time for max feed = 500 mm Sec. 1 Web Compression: Max Web Thickness (800 GSM) mm 30 Web Compression: Min Web Thickness (800 GSM) +/0.5 mm 3 Web Evenness; Weight deviation, see FIG. 19 % +/2 Sub-System Operational Conditions Max Noise Level (with covers) dB 80 Temperature C. 10-40 Humidity % RH 30*-90 *Note: if the In-Let Air holds a humidity of 55-70% RHD, no machine humidification is needed.

5 Complementary Specifications for Mill-to-Web Sub System:

General Items:

[0244] Unwind stand for pulp. Two reals 1200508 mm with manual locking of reals in place. Core diameter 3 [0245] 1 300 mm fibre hood with inspection window between Mill Sub-Unit and Web forming Sub-Units. [0246] Mounted on Fibre Sub-Assembly Framework, bolted on to the Clamping-Unit Sub-System. [0247] HMI Touch Panel and Operator Alert Lamp are mounted on top of the MTW and its roof panel.
Humidification Unit for Process Air, Max 5 000 m3/h: [0248] Optional humidification of incoming air AI inside Air In-Let Cover Humidification I; see FIG. 13, 107, and/or web before Kissing Point (KP) Humidification II; see FIG. 13, 108, is done be using hydraulic 2 pcs spray nozzles at Humidification I and 2+2 pcs. (top and bottom) at Humidification II: [0249] Model: 8HPWMD driven by 6 bar water

Mill Sub-Unit:

[0250] Model 450 kg Double feeders. [0251] Saw-Tooth Mill dia. 310 mm [0252] Mill Motor 30 KW; Frequency converter controlled. Up to 5000 rpm. [0253] Feeders (PU/PL and WR) driven by 2 pcs. Servo Motors 0.9 KW; [0254] Web-evenness in basis weight (GSM)

Web Forming Sub-Unit:

[0255] PulPac Design; see drawings. [0256] Rubber Coating on Drive Roller (1:4.3) Shore A=95. [0257] Wire Belt: End-less or Seamed 3m width 580 mm. Recommended Belt Tension: 300 daN/m [0258] Air permeability: CFM ( w.c.): 550; m.sup.3/m.sup.2/h (100 PA): 8 900 [0259] Web Evenness; Basis weight deviation from average: Max+/2%/per piece, see FIG. 26.

[0260] FIG. 26 schematically shows Web Forming Evenness between 9 samples in a 500500 mm web. [0261] Belt and compacting roller is driven by 2 pcs. Servo Motors 0.9 KW; Model: See Appendix A

Vacuum Fan

[0262] ATEX classified; Motor 37 KW; IP 55 [0263] 5000 m3/hrs. at 10 000 Pa under pressure, see fan curve below.

[0264] FIG. 27 schematically shows Web Quality Sampling

2.2 Tissue Sub-System

[0265] FIG. 28 schematically shows Tissue Sub-System (2)Sub-Units, seen from Left-Front.

[0266] The Web (P: 2) leaving the Mill-to-Web Sub-System (1) should be layered with a Upper Tissue (TU) and a Lower Tissue (TL), at the Kissing Point (KP), before entering the Tool Feeder.

[0267] In most applications, where the fibre product requires barriers towards water and/or oil, the tissue is pre-coated with a small amount (<1% w.) of sustainable barrier chemistry, e.g., AKD wax. When formed in the tool, using high pressure and high temperature, the barrier chemistry will penetrate into the fibres (1:2) and seal the fibres to create the desired properties of the final fibre product. In some cases, after-curing might be needed to obtain full barrier properties.

[0268] In other cases the converter (customer) might preferred coloured or pre-printed tissue to enhance the aesthetic properties of the finished fibre product.

[0269] FIG. 29 schematically shows Tissue Sub-System (2)Sub-Units, seen from Right-Back.

[0270] In contrast to the Pulp (P: 1) the Tissue (P: 3) is a thin a fragile paper sheet that easily breaks if path tension is too high. In order to ensure a tissue tension of 10-100N the Tissue Sub-System is equipped with driven Tissue Roll Axis (2:1) where the Tissue Roll is manually clamped with a Toggle Handle (2:2). Each roll is driven by a Servo Motor (MS5/MS6) via a worm gear (2:8) and controlled in a feedback loop in PLC using a Tissue Buffer & Tension Pivot Sensor (Dance arm) (2:4, 2:9 and SA 1), see FIG. 30 below.

[0271] The Fan (1:5) belongs functionally to the Web Forming Sub-Unit, see 2.1.3 but is mounted on Tissue Framework (2:7) and is shown in these figures as part of this Sub Assembly.

[0272] FIG. 30 schematically shows a Tissue Feeding Assembly.

[0273] The Pivot Roller (2:4) rests with a small contact force (FT) inside a tissue loop, se fig. XX above, and pivots around the Tissue Roll Axis (2:1) with a Pivot Arm (2:9). The Pivot Arm has one longer arm, outside the cover plate, see chapter 2.5, and one shorter arm on the inside of the cover plate.

[0274] The shorter arm is connected to a pneumatic cylinder (2:5), that balances the weight of the Pivot Arm (2:9 & 2:4) to the correct contact force (FT), and a linear potentiometer, the Tissue Buffer & Tension Sensor (SA1 & SA2) that measures the position of the Pivot Roller (2:4), i.e., the amount of tissue in the buffer. This value is then feedbacked looped to the regulator for the Servo Motor (MS6) to rotate the tissue roll in the right speed to maintain the buffer needed. The tension of the tissue (10 and 100N) is manually set by the pneumatic cylinder (2:5).

[0275] FIG. 31 schematically shows a Tissue Feeding AssemblyExploded View.

[0276] FIG. 32 schematically shows Manual Tissue Splicing.

[0277] Each Tissue roll is lasting around 10 hours in continuous production. Two sensors (laserSA3 and SA4), see FIG. 28, measures the roll diameter for each tissue roll. The PLC tells the Operator when less than 30 min of operation is left respectively alarms when only five minutes are left before empty roll. The Splicing of Tissue Rolls is done manually upon alerts from the Operator's Alert Lamp on top of the machine and the HMI, by pausing the operation in Scala and joining the two sheet ends with a special compostable tape. Estimated stop time is less than 2 minutes per roll.

2.2.1 Tissue Sub-System Functional Requirement Specification

TABLE-US-00011 Tissue Input Max Tissue reel diameter mm 800 Tissue Reel core diameter Inch/mm 3/76 Max Tissue Reel width mm 508 Max Tissue Reel weight kg 180 Buffer capacity of the Pivot Arm mm 680 Tissue & Web Out-Put Max Web & Tissue Feeding Speed m/sec 0.75 Max time for max feed = 500 mm sec 1 Max Feeding Length per cycle; mm 500

Complementary Specifications for Tissue Sub System:

Tissue Unwind

[0278] General [0279] Max height to top reel centre: 1800 mm. [0280] The working range of the pivot arm (2:4) arm is +20 degrees, about 340 mm, i.e. the buffered tissue length of max 500 mm is within the range of the pivot arm; 2340=680 mm. [0281] Distance sensor for measuring the diameter of the reel (measuring range 400-1200 mm, Balluff). [0282] Track tension range 10-100N measured from the Pivot Arm.

2.3 Molding Sub-System

[0283] FIG. 33 schematically shows The Moulding Sub-System-seen Front/Left

[0284] The Moulding Sub-System comprises three Sun-Units:

TABLE-US-00012 3:1 Clamping Unit 3:2 Feeder (2: One Upper and One Lower) 3:3 Tool

[0285] On the following described and specified one by one. (The two Tissue Rollers (TR) shown in Fig. belongs to the Mill-to-Web Sub-System and is shown as a reference for the Kissing-Point (KP).)

2.3.1 Clamping Sub-Unit

[0286] FIG. 34 schematically shows The Clamping Unit Main Components-seen Back Left

[0287] The Clamping Unit (3:1) in Scala is a standard clamping unit from an injection moulding machine, i.e., a horizontal press, and will not be described in detail in this document. However, the main components of this sub-unit are:

TABLE-US-00013 Pos. Main Component Note 3:1.1 Fixed Platen 3:1.2 Moving Platen 3:1.3 Ejector Cylinder 3:1.4 Toggle Arms 3:1.5 Tie Bar X4 dia. 90 mm 3:1.6 Moving Platen Tie Bar rotation Position Mechanism 3:1.7 Clamping Cylinder 3:1.8 Motor Tie Bar rotation 3:1.9 Hydraulic Valve Package MS13 Servo Motor For Clamping Cylinder Hydraulic Pump 3:1.11 Tank Hydraulic Oil 3:1.12 Stand Framework

[0288] The force and movement from the hydraulic Clamping Cylinder (F.sub.h) (3:1.7) is transferred by the toggle arms into an exponential movement with high speed and low force near the open set and low speed and high force near the closed see (=180).

[0289] FIGS. 35a and 35b schematically show The Clamping Unit, FIG. 35a and Clamping unit Force Characteristics (empirical measured), FIG. 35b.

2.3.2 Feeder Sub-Unit

[0290] FIGS. 36 and 38 schematically show Feeder Sub-Unit-Web Feeder Shown closed.

[0291] FIG. 37 schematically shows two Feeder Sub-Units.

[0292] In order to secure a reliable and controlled feeding of the Web (P: 2) with Tissue to the Tool (3:3) and Waste Web out of the tool area, two Feeder Sub-Units (3:2), with two servo Motors each, are used: [0293] Upper Web Feeder [0294] Lower Waste Feeder

[0295] Each Feeder (3:2) is equipped with two pneumatic cylinders (3:2.2) that creates a nip force (WN) between the two rubber coated rollers (3:2.1). The pressure of the cylinders is manually adjusted on a regulator and manually opened by a valve for service and threading of new web.

[0296] The Upper Web Feeder and the Lower Web Feeder are almost identical, why a general Feeder (3:2) is described here. The Upper Feeder should however be possible to move into a service position (SO) when loading and un-loading tools.

[0297] Scala is designed for intermittent feeding of the Web, in the following called Stop-and-Go. Since earlier Fibre Moulding Machines has been based on continuous forming of the web, a buffer system may accumulate enough web length to be able to allow the Web feeder to rapidly feed new web into the tool area.

[0298] Scala has no buffer between the Mill-to-Web and the Moulding Sub-System. I.e., all Servo Motors (MS3, MS4, MS7, MS8, MS9 and MS10) operates simultaneously in a Stop-and-Go sequence. However, the Pulp and Tissue rolls has too much torque inertia to be operated at Stop-and-Go why (MS1, MS2, MS5 and MS6) operates at continued speed. The same goes for the Recycling Sub-System (4), see next chapter.

[0299] Each Feeder (3:2) uses two Feeder Rollers (3:2.1) and two Servo Motors (MS7 and MS8; for the upper Web Feeder and MS9 and MS10; for the lower Waste Feeder). The reason for double Servo Motors in each feeder is the need for adjusting the rotation speed individual on the two roller. Layered Tissue tends to bulge out from the Web (P: 2) and also the entire Web is a fluffy and organic material that might require different peripheral roller surface speed to not be damage by shear stress. The different might be very small and is set in the HMI upon loading of new material and basis weight.

[0300] FIG. 39 schematically shows a Feeder Roller Assembly (Exploded view)

[0301] One Feeder Roller Assembly is built inside a dia. 170 mm rubber coated sleeve roller (3:2.1). A drive flange (3:2.7) is mounted inside the sleeve and the Servo Motor (MS7) with Planetary Gear (3:2.5) is inserted through Feeder Roller Gables (3:2.6). The Feeder Roller Assembly is guided on the Slide Bars (3:2.3) by Slide Guides (3:2.8).

[0302] Each Feeder Roller Assembly pair can be adjusted in the sliding direction to feed the Web on a proper distance from the Tools in open state. I.e., manual adjustment needed for each tool with new tool thickness.

2.3.3 Tool Sub-Unit

[0303] A Female-(3:3.2) and a Male-(3:3.1) Tool System is respectively mounted on the Clamping Unit Moving Platen (3:1.2) and the Fixed Platen (3:1.1). The Moving Platen (3:1.2) is moved by the Toggle System and closes and opens the Tools, (thus temporary creating a gap (G) of the Tool Systems).

[0304] FIG. 40 schematically shows The Tool Sub-System in perspective with open

Tools and Cut Web.

[0305] A tool for Dry Moulded Fibre requires additional know-how compared with the design of Injection Moulding Tools and/or Thermo Forming Tools for Thermo Plastics. This document is not covering design guidelines for tools for Scala. Please consult with a certified PulPac Tool Maker or directly to PulPac AB for guidance.

[0306] However, here follows an overview introduction, using a typical single use fibre lid, dia. 100 mm, as an example.

[0307] FIG. 41 schematically shows A Typical 9-cavity Tool Sub-System setup.

[0308] All tools are heated, normally using heat resistor inserts, to typically 150-180 C.

[0309] A multi cavity Tool (3:3) for Dry Moulded Fibre can preferably be made up of several single mould cavities (3:3.1 and 3:3.2). The single mould cavities are mounted on a Mother Plate (3:3.3) and an Insulator Plate (3:3.4) to decrease heat losses to the Clamping Unit.

[0310] The following description presents a single cavity mould, equipped with in-mould cutting, for producing a lid, e.g., for yogurt cups. Please note that the reference numbers in this description does not follow the general nomenclature in this document.

[0311] FIG. 42 shows a Typical Dry Moulded Fibre Single-Use Lid Product (5:8)

[0312] FIG. 43 schematically shows a Typical Male of a single cavity mould for Dry Moulded Fibre Lid, in cross section.

[0313] FIGS. 44a-44d schematically illustrates a forming cycle A-D in a 2D cross section of the Lid tool.

[0314] Many tools includes a spring loaded (5:6)) in-mould cutting device (5:5) and a soft pressure member, made by an Elastomer (5:7), assuring an isostatic pressure, i.e. essentially equal pressure in all directions, of at least 12 MPa, see diagram in FIG. 44e.

[0315] All tools are heated to a temperature (X15) measured by Tool Temperature Sensor (SAX) in every single tool. The Operator sets the desired Tool Temperature (SAX), in the Product Recipe in HMI and the PLC controls the measured temperature via a PID-regulator.

[0316] With reference to fig. previous page the forming process can be described in four steps A-D, normally taking 3 seconds per cycle. [0317] A. The Blank/Web (P: 2) with Tissue is fed by the Tool Feeders (3:2) in the gap (G) between the open Tools (5:2 and 5:3). [0318] B. The Clamping Unit closes the two tools (5:2 and 5:3) by moving the Female Tool System (5:2). The Web is folded into the cavity between the two tools and a Spring Loaded (5:6) Cutting Device (5:5) punches (see red ring) the blanks for each cavity, using a cutting force (F1). [0319] C. The Clamping Unit further closes the tool with a force (F2) and the Soft Pressure Member (5:7) is compressed to an isostatic pressure normally set to 12 MPa by the Operator at the HMI. The fibres are then simultaneously exposed for the pressure and temperature and instant fibril aggregation, caused by hydrogen bonds, will make the fibre product (5:8) hard and stiff. [0320] D. The Clamping Unit (6) opens the tools and the ejector cylinder press all Ejectors (5:4) for ejection of the products (5:8). The residual Web (3:5) will be transported out from the tools by the Waste Feeder, at the same time as new Web is fed in accordance with A above.

[0321] The Blank Web width of 500 mm and the outer size of the Clamping Unit Platens of 815815 mm defines the available area for a multi cavity tool system.

[0322] FIG. 45a schematically shows a Multi Cavity Tool with 9 cavities and FIG. 45b schematically shows an excerpt from FIG. 45a with 4 cavities.

[0323] In most cases the available tool mounting area, see dotted rectangle in FIG. 45, limits the number of cavities, rather than the available Pressing Force (X16) of 3 000 kN (300 ton). In this example, with round products (d=100 mm) and No. of cavities (n) is 15 and a preferred forming pressure (X14) of 12 MPa, the required Pressing Force (X16) is calculated as:

[00001]$X16=n\left[F1+F2\right]=n\left[F1+P\frac{d^2}{4}\right]$

[0324] X16=1 713 kN (173 ton); The Cut Force (F1) in this example is 20 kN/cavity

[0325] The preferred Forming Pressure (X14) or Pressure Force (X16) is defined in the product recipe section of the HMI.

2.3.4 Web Forming Sub-System Functional Requirement

[0326] The first Scala prototypes are using a Servo Hydraulic Clamping Unit HRU 300FC from Huarong Plastic Machinery Ltd.

TABLE-US-00014 Unit Specification Item Clamping Unit* Clamping Force kN 2500 (up to 3000) Tie Bar Distance mm 555 555 Opening Stroke mm 200 Tool (Mould) Thickness mm 200-300 Mould Platen mm 815 815 Ejector stroke mm 160 Servo Motor (MS13) kW 34 System Pressure Bar 140 Weight tons 6 Item Feeder Roll Dia. mm 170 Rubber Coating Hardness (3:2.1) Shore A 60 Servo Motor (MS7, MS8, MS9 and kW 0.9 MS10) Ratio Planetary Gear (3:2.5) 0.05 Max Feed Length mm 500 Max Nip Force (WN) N 1000 Item Tool See separate Drawings. Mould Pressure MPa >12 Mould temperature C. 150-180 *However, any type and size of clamping unit can be used.

2.4 Recycling Sub-System

[0327] FIG. 46 schematically shows The Recycling Sub-System, seen from Front/Left.

[0328] The residual web (P: 3), after forming and punching out the products, including tissue coated with barrier chemicals, is possible to feed back to the Saw tooth Mill (1:2) for defibration again and re-use for new fibre products. The re-circulated fibres will reach a steady state level after a numbers of run and the milled tissue and additional levels of Barrier Chemicals will reach acceptable levels for forming and food grade approvals.

[0329] The waste web (P: 3) needs however to be hard compressed into a stiff sheet to be able to defibrate in the mill again, similar to the raw pulp. This compression is done in the Compression Unit followed by a transportation belt, constituting the Recycling Sub-System (4), see FIG. 47

[0330] FIGS. 47a and 47b schematically show The Recycling Sub-System, seen from Back side.

[0331] Two Compression Rollers (4:1 and 4:2) are driven by Servo Motor (MS11) and a double-sided cog belt (4:3). The two rollers are supported by double roll bearings in each end, to withstand the Compression Force (Fc max=100 kN). The bearings of the Lower Roller (4:2) are supported by an Eccentric Ring (4:4) hosting a trapezoidal thread in its periphery. The Compression Force (Fc), or more correct, the geometrical distance between the two Compression Rollers are manually adjusted by turning a trapezoidal threaded Screw (4:5).

[0332] The roller distance can be adjusted between 0 and 4 mm. The thickness (t) of the Compressed Waste Web with Tissue (P: 3) will always be larger than the nip gap due to spring back in the fibre structure. A typical thickness of the Waste Web (t) is however 2-6 mm.

[0333] The Compression Rollers and the Mill Feeder are operated in a continuous motion and is not comprised by the Stop-and-Go motion in the Moulding Sub-System. I.e., a Waste Buffer, see previous fig., will store 0.5 m within each cycle. A Pivot Arm Sensor (SA3) measures the position of the Buffer Bulge to avoid Web path breakage.

[0334] A Belt Conveyor (4:6), driven by Servo Motor (MS12), transports the compacted Waste Web (P: 3) to the inlet of the Mill (1:2).

2.4.1 Recycling Sub-System Functional Requirement

TABLE-US-00015 Item Clam Unit Specification Compacting Roller Dia. mm 140 Max Compacting Force kN 100 Roller Nip Gap adjustment (Manually) mm 0-4 Compression Motor (MS11) W 1500 Planetary Gear ratio (MS11) 0.025 (1:40) Drive Torque -Compression Nip Nm 4460** Servo Motor (MS12) -Belt Conveyor W 900 **If the compression unit will be overloaded it is expected that the torque watch of the servo will force the entire system into an emergency stop.

2.5 Covers Sub-System

[0335] FIG. 48 schematically shows Scala with Covers

[0336] The functional purpose of the covers is to protect users from injuries and to lower noise less than 80 dB. Several sensors register the open/close status of openable covers and disable start-up or emergency stop the machine if opened in automatic mode.

[0337] FIG. 49 schematically shows The Cover Sub-System-Exploded view

TABLE-US-00016 Pos. Cover Spec. Note 6:1 Front Door O 6:2 MTW Front Door I + O + G 6:3 Clamping Unit Lower Front 6:4 MTW Lower Front 1 6:5 MTW Lower Front 2 6:6 MTW Lower Gable Gills for ventilation 6:7 Pulp In-Let Gable I 6:8 Air In-Let Gable I With water nozzles 6:9 MTW Lower Back 6:10 MTW Upper Back With Tissue In-Let 6:11 Tissue Right Gable I 6:12 Fan Motor Air In-Let I 6:13 Tissue Sub-System Back I 6:14 Tissue Sub-System Top I 6:15 Tissue Left Gable I 6:16 MTW Top I 6:17 Upper Tissue Top Cover O + G 6:18 Kissing Point Cover I + O 6:19 Clamping Unit Top O + G 6:20 Clamping Unit Back Gable H 6:21 Clamping Unit Back Door H 6:22 Clamping Unit Back H Window 1 6:23 Clamping Unit Back H Window 2 6:24 Clamping Unit Gable H 6:25 Clamping Unit Lower Gable H Gills for ventilation 6:26 Clamping Unit Upper Front

[0338] The Spec. code in table above:

TABLE-US-00017 I Noise Insulated; to be specified in later issue O Openable; see chapter 1.4 G With Gas springs H Huarong Original

[0339] The glass in the Front Door (6:1) is made by Polycarbonate. The glass in MTW Front Door (6:2) is two layer insulation hardened and un-crushable in order to secure food safety.

3.0 Human Interface (HMI)

[0340] FIG. 50 schematically shows a Human Interface of Scala and thus a control unit 113.

[0341] The HMI Panel specification of Scala is: [0342] Full 19201080 pixel HD resolution (16:9) [0343] TFT-LCD touch screen [0344] 1.5 GB application memory [0345] Ethernet 2100 Mbit [0346] 0 C. to +50 C. operating temperature [0347] CE, FCC, UL approvals

[0348] The touch screen panel is mounted on a swing arm enabling the operator to elevate and tilt the panel in the horizontal plane for optimal access by the sliding door.

[0349] FIG. 51 schematically shows an HMI Panel 114, measurements in mm

TABLE-US-00018 APPENDIX A APPENDIX A; SERVO MOTORS SCALA MOTOR Max Speed Power GEAR I: Mounted on Motor GEAR II: Transmission MS No. Function rpm Watt Type In Out Ratio Type In Out Ratio MS01 Pulp Sheet Feeder 2500 900 Planetary 40 1 0.025 Timing Belt 36 36 1 MS02 Waste Web Feeder 2500 900 Planetary 40 1 0.025 Timing Belt 36 36 1 MS03 Wire Belt Drive 2500 1500 Planetary 40 1 0.025 Timing Belt 72 36 2 MS04 Web Compression 2500 1500 Planetary 40 1 0.025 Timing Belt 72 36 2 MS05 Upper Tissue Roll Drive 2500 1500 Worm 100 1 0.01 Direct 72 36 2 MS06 Lower Tissue Roll Drive 2500 1500 Worm 100 1 0.01 Direct 72 36 2 MS07 Feed Into Tool Roller 1 2500 900 Planetary 20 1 0.05 Timing Belt 1 1 1 MS08 Feed Into Tool Roller 2 2500 900 Planetary 20 1 0.05 Timing Belt 1 1 1 MS09 Feed Out of Tool Roller 1 2500 900 Planetary 20 1 0.05 Timing Belt 1 1 1 MS10 Feed Out of Tool Roller 2 2500 900 Planetary 20 1 0.05 Timing Belt 1 1 1 MS11 Waste Compression 2500 1500 Planetary 40 1 0.025 Timing Belt 22 36 0.61 MS12 Waste Transporter Belt 2500 900 Planetary 40 1 0.025 Timing Belt 36 36 1 MS13 Hydraulic Servo Pump GEAR III: Roller Periphery Dia. Circumference MS No. Function Drive Surface mm mm MS01 Pulp Sheet Feeder Straigth Knurled 65 204.2 MS02 Waste Web Feeder Belt Drive 65 204.2 MS03 Wire Belt Drive Rubber Coated 111.9 351.5 MS04 Web Compression Steel 110 345.6 MS05 Upper Tissue Roll Drive Full Tissue Roll 800 2513.3 Empty Tissue Roll 101 317.3 MS06 Lower Tissue Roll Drive Full Tissue Roll 800 2513.3 Empty Tissue Roll 101 317.3 MS07 Feed Into Tool Roller 1 Rubber Coated 120 377 MS08 Feed Into Tool Roller 2 Rubber Coated 120 377 MS09 Feed Out of Tool Roller 1 Rubber Coated 120 377 MS10 Feed Out of Tool Roller 2 Rubber Coated 120 377 MS11 Waste Compression Steel 140 439.8 MS12 Waste Transporter Belt Belt Drive 140 439.8 MS13 Hydraulic Servo Pump CALCULATIONS Max. Tangential Feed Total Max Feed Max Feed Estim. Min Max Roller Nip Force MS No. Function mm/Motor Turn Ratio mm/min mm/sec Cycle Sec. rpm N MS01 Pulp Sheet Feeder 5.105 0.025 12 763 213 2.74 62.5 3520 MS02 Waste Web Feeder 5.105 0.025 12 763 213 2.74 62.5 3520 MS03 Wire Belt Drive 17.577 0.05 43 943 732 1.14 125 1704 MS04 Web Compression 17.279 0.05 43 197 720 1.16 125 1733 MS05 Upper Tissue Roll Drive 50.265 0.02 125 664 2 094 0.4 50 596 6.346 0.02 15 865 264 3.15 50 4719 MS06 Lower Tissue Roll Drive 50.265 0.02 125 664 2 094 0.4 50 596 6.346 0.02 15 865 264 3.15 50 4719 MS07 Feed Into Tool Roller 1 18.85 0.05 47 124 785 1.06 125 953 MS08 Feed Into Tool Roller 2 18.85 0.05 47 124 785 1.06 125 953 MS09 Feed Out of Tool Roller 1 18.85 0.05 47 124 785 1.06 125 953 MS10 Feed Out of Tool Roller 2 18.85 0.05 47 124 785 1.06 125 953 MS11 Waste Compression 6.72 0.015 16 799 280 2.98 38.19 4457 MS12 Waste Transporter Belt 10.996 0.025 27 489 458 1.82 62.5 1634 MS13 Hydraulic Servo Pump BEUER: Article No. MS No. Function Servo Motor Servo Driver MS01 Pulp Sheet Feeder BSD-FEP09AMK-4 (71201) BSD-L7NHB010U-4 MS02 Waste Web Feeder BSD-FEP09AMK-4 (71201) BSD-L7NHB010U-4 MS03 Wire Belt Drive BSD-FEP15AMK-4 (71202) BSD-L7NHB020U-4 MS04 Web Compression BSD-FEP15AMK-4 (71202) BSD-L7NHB020U-4 MS05 Upper Tissue Roll Drive BSD-FEP15AMK-4 (71202) BSD-L7NHB020U-4 MS06 Lower Tissue Roll Drive BSD-FEP15AMK-4 (71202) BSD-L7NHB020U-4 MS07 Feed Into Tool Roller 1 BSD-FEP09AMK-4 (71201) BSD-L7NHB010U-4 MS08 Feed Into Tool Roller 2 BSD-FEP09AMK-4 (71201) BSD-L7NHB010U-4 MS09 Feed Out of Tool Roller 1 BSD-FEP09AMK-4 (71201) BSD-L7NHB010U-4 MS10 Feed Out of Tool Roller 2 BSD-FEP09AMK-4 (71201) BSD-L7NHB010U-4 MS11 Waste Compression BSD-FEP15AMK-4 (71202) BSD-L7NHB020U-4 MS12 Waste Transporter Belt BSD-FEP09AMK-4 (71201) BSD-L7NHB010U-4 MS13 Hydraulic Servo Pump NOT SPECIFIED HERE NOT SPECIFIED HERE

REFERENCE SIGNS-NOT ALL REFERENCE SIGNS ARE LISTED

[0350] 100: Cellulose product machine, also called Scala in the description [0351] 101: Cellulose product [0352] 102: Cellulose blank structure [0353] 102a: First surface, Cellulose blank structure [0354] 102b: Second surface, Cellulose blank structure [0355] 103: First transport unit [0356] 104: Mill [0357] 104a: Forming hood (1:3) [0358] 104a1: first opening [0359] 104a2: second opening [0360] 104b: Suction box [0361] 104b1: Fan [0362] 105: Forming mould [0363] 105a: First mould part [0364] 105b: Second mould part [0365] 106: Cellulose-based material [0366] 106a: First tissue layer [0367] 106b: Second tissue layer [0368] 107: Water added before or in the mill [0369] 108: Water added before or in the mill [0370] 109: Second transport unit [0371] 110: Residual cellulose fibre structure [0372] 111: Conveyer belt wire belt [0373] 112: First side of conveyer belt [0374] 112b: Second side of conveyer belt [0375] 113: Control unit [0376] 114: Display unit of the Control unit [0377] 115: Return buffer unit