Abstract: A calender press for use in a paper-making machine includes a top roll positioned adjacent to a nip and rotatable about a longitudinal axis thereof. The top roll has a length and circumferential perimeter. The length extends in the direction of and is longer than the width of the fiber web. The top roll is thermally compensated in a plurality of thermal zones which are adjacent to each other across the length of the top roll, whereby the perimeter of the top roll may be adjusted in a locally adjustable manner toward and away from the nip. A bottom roll is positioned adjacent to the top roll and defines the nip with the top roll. The bottom roll is rotatable about a longitudinal axis thereof and has a length and circumferential perimeter. The length extends in the direction of and is longer than the width of the fiber web. The perimeter is smaller at each longitudinal end of the bottom roll and larger at approximately a midpoint between the longitudinal ends, thereby defining a crowned bottom roll.

Abstract: A paper machine includes a traveling belt for carrying a fiber web, and a cutting device disposed below the belt for cutting the fiber web into smaller pieces. The cutting device has an inlet and an outlet. A guiding device guides the fiber web from the belt to the inlet of the cutting device. A pulper is connected with the outlet of the cutting device for receiving the smaller pieces of fiber web from the cutting device. The traveling belt may be in the form of, e.g., a wire, felt or water impervious belt. The cutting device may be in the form of, e.g., a shredder, fluffer, water jet cutter, laser cutter and/or roll cutter.

Abstract: A method of continuously loading fibers in a fiber suspension with calcium carbonate. The fibers include a fiber wall surrounding a lumen. A reactant solid in the form of calcium oxide and/or calcium hydroxide is mixed into the fiber suspension with a resultant initial process pH of between 11 and 12. The fiber suspension is transported at a consistency of between approximately 15 and 30% into an inner chamber of a closed reactor. A reactant gas is injected into the reactor, whereby the reactor is pressurized to a pressure between 5 and 150 psi. A temperature of the fiber suspension within the reactor is controlled at a range between −10° C. and 80° C. The fibers within the fiber suspension are loaded with calcium carbonate as a result of a chemical reaction between the reactant solid and the reactant gas in the reactor over a predetermined reaction time.

Abstract: The invention is directed to a method of aligning a bearing assembly relative to a roll in a fiber-making machine. The method of the present invention is particularly adapted for dryer cylinders in a paper-making machine, the dryer cylinders having an end rotatably mounted in a preferably freely carrying bearing assembly such as a continuous aligning roller bearing (CARB) that allows for axial (z direction) movement of the cylinder particularly axial movement due to thermal expansion. The bearing assembly includes inner and outer races of which the outer race is stationary with the inner race is affixed to the journal and moves therewith. For axially aligning or providing an initial offset of the outer race to the inner race, an alignment plate is mounted to the end of the cylinder journal during bearing housing installation that allows various measurements to be taken.

Abstract: A revolver valve includes a housing with a cylindrical inner chamber, and a pair of end caps respectively attached to each end of the housing. One of the end caps includes an inlet opening and the other end cap includes an outlet opening. A cylindrical rotor body is rotatably disposed within the inner chamber of the housing. The rotor body includes a pair of end faces respectively positioned closely adjacent to the end caps, and a plurality of longitudinally extending cylinders extending between the end faces. Each cylinder is positioned generally concentrically about an axis of rotation of the rotor body, whereby the plurality of cylinders are sequentially disposed in communication with the inlet opening and the outlet opening during rotation of the rotor body within the inner chamber during use. The revolver valve is preferably used in a fiber stock preparation system in conjunction with a fiber loading apparatus having a pressurized vessel.

Abstract: A paper-making machine includes a traveling substrate and a roll carrying the substrate. The roll includes a carbon fiber shell, a ceramic layer over the shell, and a polytetrafluoroethylene layer over the ceramic layer. The polytetrafluoroethylene layer defines an outer surface of the roll. The ceramic layer intermittently extends through the polytetrafluoroethylene layer to the outer surface of the roll.

Abstract: A device for processing a continuous fiber web includes a membrane, a pressurized enclosure, a tension roll and a guide roll. The pressurized enclosure includes at least a first roll and defines an air press chamber. The first roll partially defines the air press chamber and carries the membrane. The tension roll also carries the membrane and is movable toward and away from the first roll. The guide roll further carries the membrane and is positioned between the first roll and the tension roll. The guide roll has opposite ends, at least one of which is pivotable toward and away from the first roll.

Abstract: A method of processing recycled waste paper includes pulping waste paper in a first drum pulper. White fibers are separated from the waste paper in a first screen drum. The white fibers are then processed by screening, cleaning, deinking and bleaching. The remaining waste paper is pulped within a second drum pulper. The brown fibers are separated from the waste paper in a second screen drum. The brown fibers are processed by screening, cleaning and bleaching.

Abstract: A paper-making machine includes at least one roll for carrying a fiber web or a belt. At least one of the rolls includes a shell formed from a composite material; a journal comprised of metal; and a head interposed between and interconnecting the shell and the journal. The head is also formed from a composite material.

Abstract: A paper machine for making a fiber web includes an approach flow system with a plurality of control modules. Each control module controls one of a plurality of adjustable input parameters. A wet end receives a fiber suspension from the approach flow system, and includes a headbox which discharges a fiber suspension with a known cross sectional profile onto a wire. A press section, forming section and drying section are used to press form and dry the fiber web, respectively. A plurality of sensors are respectively positioned in association with the approach flow system, wet end, press section, forming section and/or drying section. Each sensor is configured to sense a physical characteristic of the fiber suspension or fiber web and provide an output signal indicative thereof. A chemistry process controller is coupled with each sensor and each control module within the approach flow system to define a closed loop control system. The chemistry process controller controls operation of each control module.

Abstract: A multi-ply fiber web forming apparatus includes a lower forming fabric defining a lower forming fabric run. A first headbox is positioned above the lower forming fabric for discharging a fiber suspension onto the lower forming fabric. An upper forming fabric defines an upper forming fabric run. A second headbox is positioned above the upper forming fabric for discharging a fiber suspension onto the upper forming fabric. A wet forming box is positioned below the lower forming fabric for applying a liquid to the lower forming fabric. A transfer roll is positioned above the upper forming fabric. The transfer roll and the wet forming box are positioned in close opposing relationship to each other, whereby each of the lower forming fabric and the upper forming fabric pass therebetween in a transfer area.

Abstract: A method of manufacturing a suction roll shell for use in a paper-making machine utilizes a mandrel with a length and a cross-sectional area corresponding to the shell. The mandrel has a plurality of generally radially extending holes. A plurality of pins are placed in the holes, with each pin extending radially outward from the shell a distance greater than a desired thickness of the shell. At least one elongate fiber is wound around the mandrel to form the shell with the desired thickness. The pins are removed from the mandrel and the shell.

Abstract: A pulper in a stock preparation system includes a housing with a fiber inlet, at least one water inlet, at least one outlet and an inner chamber. A plurality of stationary pulping foils are attached to the housing and extend into the inner chamber. A rotatable shaft assembly extends through the inner chamber. The shaft assembly includes a shaft, an auger positioned around the shaft and relative to the fiber inlet and a plurality of movable pulping foils carried by and extending from the shaft. A conical valve is positioned in association with the outlet and is selectively movable to open and close the outlet.

Abstract: A roll grinding system includes a roll with a pair of longitudinally opposite ends, a longitudinal axis extending between the ends, and an outer surface. A material removal tool is movable in a travel path along a length of the roll. The material removal tool has a generally flat working surface oriented generally parallel to the travel path. A longitudinal displacement drive is connected with the material removal tool for moving the material removal tool along the travel path. A pair of supports are respectively positioned at and rotatably carry a corresponding end of the roll. At least one transverse displacement drive is provided, with each transverse displacement drive being connected with a corresponding support and configured to move the corresponding support in directions generally toward and away from the longitudinal axis.

Abstract: A pulper for pulping a fiber suspension includes a vessel, an extraction plate assembly and a rotor. The extraction plate assembly is disposed within the vessel and includes a metal plate with a plurality of holes extending therethrough. A plurality of metal inserts are respectively disposed within the holes and project from the plate. Each insert is removably attached to the plate. A rotor is disposed within the vessel adjacent to the extraction plate assembly. The inserts are removably attached to the plate by brazing the inserts within the holes, or slightly shrinking the inserts using liquid nitrogen and placing the inserts in the holes.

Abstract: A method and apparatus for measuring thickness of a fiber material during manufacture of the fiber material, especially paper in a paper-making machine, comprises a gamma radiation transceiver in communication with a processing/control system. The gamma radiation transceiver is placed at a points along the production path of the web of paper being produced and liberates gamma radiation towards the fiber material. Backscatter of gamma radiation is received by the gamma transceiver also which generates corresponding signals that are received by the processing/control system. The processing/control system processes the signals to determine a thickness profile along a cross-section of the web. The processing/control system may be in communication with or considered a subset of a main processing/control system for the paper-making machine. A gamma radiation shield may be used with the gamma transceiver and is mounted on the side of the paper web opposite the gamma transceiver.

Abstract: A paper-making machine for making a fiber web, includes a wire for carrying the fiber web. A trim squirt includes a nozzle cutter and an accumulator tank. The nozzle cutter is directed toward and transverse to the wire. The accumulator tank includes an inlet for receiving a pressurized fluid and an outlet fluidly connected with the nozzle cutter. The tank is structured and arranged to define an air attenuation pad therein.

Abstract: A revolver valve includes a housing with a cylindrical inner chamber, and a pair of end caps respectively attached to each end of the housing. One of the end caps includes an inlet opening and the other end cap includes an outlet opening. A cylindrical rotor body is rotatably disposed within the inner chamber of the housing. The rotor body includes a pair of end faces respectively positioned closely adjacent to the end caps, and a plurality of longitudinally extending cylinders extending between the end faces. Each cylinder is positioned generally concentrically about an axis of rotation of the rotor body, whereby the plurality of cylinders are sequentially disposed in communication with the inlet opening and the outlet opening during rotation of the rotor body within the inner chamber during use. The revolver valve is preferably used in a fiber stock preparation system in conjunction with a fiber loading apparatus having a pressurized vessel.

Abstract: A roll grinder system including a roll grinder bed of high dynamic stiffness, having a roll support and a grinding wheel support fixedly mounted to the roll grinder bed. The roll grinder bed is comprised of a monolithic epoxy granite block with a steel plate embedded in the top surface and a steel plate embedded in the bottom surface. The bed for the support for the roll being ground is rigidly affixed to the top plate. The bed for the traversing carriage of the grinding wheel head is also rigidly affixed to the top plate. A bed for the caliper is affixed to a lateral side of the block. The grinding wheel and the caliper traverse along the axis of the roll being ground. Vibration isolators are disposed below the bottom plate of the block.

Abstract: A paper-making machine or an off-line coater includes a rotatable drive unit and a rotatable driven element in the form of a roll, cylinder, pulley and/or gear. A clutch includes a rotatable input shaft coupled with the rotatable drive unit. At least one drive rotor is connected with the input shaft, and includes a plurality of magnetic coils. Each magnetic coil includes a coil winding. At least one driven rotor is positioned axially adjacent to at least one of the drive rotors. Each drive rotor includes a plurality of angularly spaced electrical conductors which are positioned adjacent to at least one of the drive rotors. A rotatable output shaft is coupled with the driven rotor and the rotatable driven element. A source of modulated direct current power is coupled with each of the magnetic coils, whereby a magnetic flux generated by the drive rotor and a coupling force between the drive rotor and the driven rotor can be varied.