Apr 21 2015
VTT Technical Research Centre of Finland, along with an international industrial consortium, has been involved in a 2.5 year project to promote the implementation of foam forming technology on a large scale.
Foam forming technology has the potential to save companies huge sums of money in paper and paperboard manufacturing. The technology can also be adapted to expand the use of natural fibres in the manufacture of recyclable and lightweight items, such as non-wovens, and insulation materials. It is possible to even reduce the weight of an item by 15–25%.
The foam forming method involves a large quantity of air, in the form of small bubbles, being blended to a water-fibre suspension. The properties of paper and paperboard are enhanced using this method. Moreover, raw material and energy is saved.
The €3.6 million project is focused on investigating the way current paper and board machines can be transformed to foam forming. This project will not only assist Europe in reaching its low-carbon, resource-efficiency targets, but also advocates the Finnish Bioeconomy Cluster's research approach, which is keen on producing smart and resource-efficient manufacturing technologies.
The VTT- led project was launched in February 2015. The project is basically a follow up of some development research conducted by the Finnish Bioeconomy Cluster FIBIC's research programme in 2008.
With support from the European Regional Development Fund, VTT's pilot-scale research environment for fibre processes in Jyväskylä was transformed to foam forming between 2013 and 2014.
So far, the foam forming technology has been tried and tested by various small, medium and large scale companies. New product applications have also been proven in numerous trials. One of the trials revealed a 20% drying cost reduction in papermaking. The positive results from these trials have led to many companies showing interest in this technology.
"At Valmet, we believe in the foam forming technology and the new possibilities it offers to our customers. We are just now exploring the possible applications, both at VTT and our test facility in Jyväskylä," says Sami Anttilainen, Valmet's Vice President, Technology.
The project has raised extensive interest. The following 20 industrial partners from Finland, North America, Europe and Asia are participating in the project coordinated by VTT: Albany International, BillerudKorsnäs, Domtar Paper Company LLC, International Paper Company, Irving Paper Limited, Kemira, Kimberly-Clark Corporation, Kuraray Europe, Lenzing Aktiengesellschaft, Metsä Board, Moorim SP, Pixact, Sappi, Smurfit Kappa Group, Sofidel S.P.A., Stora Enso, Sulzer Pumps Finland, UPM-Kymmene, Valmet and Wetend Technologies.
The project began with a meeting held in Jyväskylä on 5 March 2015. "It is great to see so many innovative companies, which are joining their forces to develop the foam technology further. The project will strengthen the already strong position of VTT and Central Finland as the leading centre of expertise for fibre-based products and bioeconomy. It also builds confidence that our long-term R&D work in the paper and board sector is highly valued by the companies," explains Harri Kiiskinen, VTT's Principal Scientist leading the project.
The project has received a million euro funding from the European Regional Development Fund, via the Regional Council of Central Finland.