Abstract: The non-woven web of the present invention is comprised of recycled cellulose fiber and untreated Clarifier Sludge, and optionally, recycled glass fiber. Unlike uses of reclaimed Clarifier Sludge whereby the material has been treated in some fashion to improve its quality, the non-woven web of the present invention utilizes untreated Clarifier Sludge. The Clarifier Sludge of the present invention is dry enough to handle, and in one example varies between about 30% and about 45% solids. The Clarifier Sludge can be added to web-forming equipment (e.g., papermaking equipment) either in a waste paper disintegrator or into a recycling apparatus (e.g., broke pulper) whose output is metered into a refiner tank of the web-forming equipment. In an embodiment utilizing a broke pulper for introduction of the Clarifier Sludge, the broke pulper is filled with clarifier sludge and water to a consistency of about 3.5% solids.

Abstract: The non-woven web of the present invention is comprised of recycled cellulose fiber and untreated Clarifier Sludge, and optionally, recycled glass fiber. Unlike uses of reclaimed Clarifier Sludge whereby the material has been treated in some fashion to improve its quality, the non-woven web of the present invention utilizes untreated Clarifier Sludge. The Clarifier Sludge of the present invention is dry enough to handle, and in one example varies between about 30% and about 45% solids. The Clarifier Sludge can be added to web-forming equipment (e.g., papermaking equipment) either in a waste paper disintegrator or into a recycling apparatus (e.g., broke pulper) whose output is metered into a refiner tank of the web-forming equipment. In an embodiment utilizing a broke pulper for introduction of the Clarifier Sludge, the broke pulper is filled with clarifier sludge and water to a consistency of about 3.5% solids.

Abstract: A non-woven web such as a facer comprises recycled cellulose fiber; recycled glass fiber, and, a sizing agent which provides the mat with decreased liquid penetrability over time. An example suitable sizing agent is alkenyl succinic anhydride (ASA) which has a dry basis add-on rate of from about 0.15% to about 0.4%, and preferably a dry basis add-on rate of from about 0.2% to about 0.3%. The sizing agent provides the mat with decreased liquid penetrability four weeks after mat production. In one aspect of the invention, the mats/facers can be employed as a facer for a rigid cellular foam board.