Case Study
Flat Yarn Dryer Fabric Extended Service Life by 33%
Brazil Packaging Mill — Brazil
Brazil
Metso
900 m/min
12 weeks
Project Snapshot
Country
Brazil
Paper Type
Kraft & Board
Machine Brand
Metso — 4,800 mm
Machine Speed
900 m/min
Project Duration
12 weeks
Products Used
Customer Background
One of Brazil's largest packaging paper producers, operating two wide-format machines producing testliner and fluting for the corrugated packaging industry. Annual output exceeds 350,000 tons.
The Challenge
Frequent dryer fabric replacement (every 6 months) was causing excessive maintenance costs and production downtime. The existing flat yarn fabric showed premature edge wear and uneven air permeability distribution across the full width, resulting in moisture profile variation and 12 days of annual downtime.
Key Issues Identified
- Edge wear accelerated by high-temperature exposure (180°C+) in the outer dryer sections without adequate selvedge reinforcement.
- Air permeability gradient was inconsistent across the 4,800mm width, causing uneven drying rates.
- Standard hydrolysis resistance was insufficient for the machine's steam pressure operating range.
The Solution
PAPTEX designed a custom Flat Yarn Dryer Fabric with reinforced selvedge edges, optimized air permeability gradient (650–700 CFM center to edge), and anti-hydrolysis treatment for high-temperature dryer sections. Pin seam with polyurethane coating ensured quick installation.
Root Cause Analysis
Root cause analysis identified:
1. Edge wear accelerated by high-temperature exposure (180°C+) in the outer dryer sections without adequate selvedge reinforcement.
2. Air permeability gradient was inconsistent across the 4,800mm width, causing uneven drying rates.
3. Standard hydrolysis resistance was insufficient for the machine's steam pressure operating range.
Implementation Timeline
1
Thermal Survey
Weeks 1-2Dryer section temperature mapping, air balance analysis
2
Fabric Engineering
Weeks 3-5Custom permeability gradient design, selvedge reinforcement
3
Production & Treatment
Weeks 6-9Weaving, anti-hydrolysis treatment, quality testing
4
Installation
Week 10Seam installation, tensioning, dryer profile verification
5
Results — Verified KPIs
Fabric life extended by 33%, downtime reduced by 42%, and moisture profile variation halved to ±1.0%. Annual maintenance cost savings of $120,000 plus improved sheet quality for downstream corrugator operations.
| KPI Metric | Before | After | Improvement |
|---|---|---|---|
| Fabric Service Life | 6 months | 8 months | 33% |
| Annual Downtime | 12 days/yr | 7 days/yr | -42% |
| Moisture Variation | ±2.5% | ±1.0% | — |
| Steam Consumption | 1.85 tons/ton | 1.72 tons/ton | -7% |
Return on Investment
$120,000 annual savings from extended fabric life and reduced downtime. ROI achieved within 5 months.
“The PAPTEX dryer fabric solved our edge wear problem that had plagued us for years. The 33% longer life means we now align fabric changes with planned shutdowns, not emergency stops.”
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