Click Here for an interactive schematic of the Pilot Plant layout

MTS Airlaid Pilot Plant - General Specifications

Dan-Web Airlaid FormerThe airlaid process for making wood pulp fibers into roll goods has great potential. Besides obvious environmental benefits, airlaid composite webs offer almost unlimited product development opportunities for both the paper and nonwovens industries.

Because MTS's laboratories have many years of experience with airlaid grade development and product testing, the pilot line is specially designed to offer maximum flexibility regarding recipes and basis weight. Designed from the beginning as a "test roll" development facility, a great deal of prototyping can be performed without the expense associated with running full-scale machines for concept testing. A full range of virgin and recycled fibers, particles and additives can be produced at ultrahigh or ultralow densities using latex, thermal bonding or water/pressure bonding techniques.

Production Width
  • 0.25 m

Basis Weight
  • One layer basis weight (wood pulp only measured with no latex or SAP) is 12 - 700 g/m2. Fabrics containing SAP can achieve much higher single-pass basis weights (~1500 g/m2)
  • Two separate forming heads are available with fully independent pulp and synthetic fiber feeds, allowing complex multi-layer or homogenous webs
  • Multipass is also possible to build even more exotic layered fabrics and for high basis weights

Density
  • 0.03 to about 0.3g/cm3
  • Compression rolls both before and after the dryer allow production of high bulk tissue-type webs or high density paperboard

Superabsorbent Addition
  • Homogeneous blends, tight center web SAP layers or center layer SAP mixed with fiber
  • Controllable layers with SAP injected in the center and fiber veneers on the outside
  • 0 - 90% granules, up to 100% possible with SAP fibers
  • The granular dosing and metering systems are adjustable for 3-dimensional control

Synthetic Fiber Blends
  • Synthetic fibers of most types can be handled and metered up to about 12mm in length
  • Multiple synthetic fiber metering systems allow complex blends and even 100% synthetic fiber webs

Pulp Defibration
  • Commercial Kamas H-12 hammermills and knife mill with two pulp unwinds processes 100mm wide fluff rolls with a full selection of screens and with capability of handling nondebonded pulp, non-roll waste paper, etc.

Bonding Methods
  • Latex spray bonding, calendar bonding or thermal bonding by through-dryer are all available
  • Electrically heated rolls can be used for compression or bonding
  • Latex and thermal bonding can be used alone or together. For very high basis weights an oversized through-dryer offers precise control and extra time-at-temperature capabilities
  • Wide temperature capability and very long time-at-temperature are possible
  • The extremely capable four-roll heated calendar includes air doctors for lightweights and can be configured for pattern bonding/embossing and densifying at moderate or extremely high basis weights

Terms for Typical Projects
  • US $4400/ 7 hour day
  • Raw materials are provided by the customer and returned at the end of the trial
  • Wrapping/palleting/shipping expenses are charged to the customer
    Customers renting more than 10 days/year receive discounts, depending on volume
  • Customer pilot plant equipment can be installed on MTS's line and tested. Cost is based on specifics of the project and duration

Click Here for an interactive schematic of the Pilot Plant layout


Contract laboratory testing of fabrics can be done on-site in our extensive testing lab, offering the most advanced testing equipment and skilled operators


Confidentiality is a proven commodity at MTS