Material Matters: Unveiling the Critical Role of Fiber Sourcing and Formation in the Dry Forming Process
When it comes to manufacturing technologies for fiber-based packaging, the dry forming process (also known as dry molding) stands out as a versatile, cost and resource-efficient method for creating eco-friendly packaging that has a wide range of applications.
Central to this process is the sourcing of raw materials and the mechanism behind good fiber formation, which play a crucial role in determining the structural integrity, strength, and overall quality of the final product. Dry forming is not just about 3D product formation but the whole transformation journey of cellulose fibers within its process. Keep reading as we do a deep dive into why material matters in the dry forming process.
Sustainable Sourcing of Raw Materials
As with all manufacturing processes, success heavily relies on the selection of raw materials, for what you put in invariably shapes and impacts what you get out. For that reason, here at Yangi, we only select optimal cellulose material (wood pulp), proven to yield superior dry formed products. By meticulously curating our raw material selection, we ensure a robust process that delivers uniformity in quality and transparency. Our dedicated R&D team continuously explores and evaluates new raw materials sources, expanding our material portfolio and continuously improving our offering to customers.
Within our innovative dry forming technology, Cellera, we prioritize certified wood pulp fibers sourced from sustainable forestry practices, fostering forest regeneration, biodiversity conservation, and ecosystem integrity.
By utilizing certified fresh fibers, Yangi actively contributes to forest conservation, mitigating deforestation, and minimizing habitat destruction, thus safeguarding natural resources for future generations.
Moreover, Yangi guarantees traceability and transparency in its supply chain through certified responsible forestry schemes, allowing customers to make informed choices and trust in the brand's commitment to environmental sustainability and ethical sourcing practices. This approach not only ensures superior product quality and performance but also complies with regulatory requirements and industry standards, meeting stringent quality criteria expected by our customers.
Fresh Fiber’s Impact on Product Quality
The quality of the pulp in dry forming processes is paramount for achieving consistent structural integrity, product quality and performance, and aesthetic appeal. Depending on the intended application, we carefully choose the most optimal quality in terms of origin, fiber length, and properties. In our pursuit of excellence, here are some key reasons why the quality of the pulp greatly matters in dry forming:
Product performance: The pulp's properties directly influence the final product's performance characteristics. For example, in packaging applications, the strength, durability, and moisture resistance of pulp-based products depend on the quality of the pulp used and ensure that the desired performance requirements and adequate protection for the packaged contents are met.
Structural integrity: High-quality pulp ensures the structural integrity of the formed product. Pulp with uniform fiber distribution and appropriate fiber length contributes to the strength and stability of the final product. If the pulp quality is compromised, it may lead to weak spots, structural defects, or even product failure.
Consistency: Consistency in pulp quality is essential for achieving uniformity in the formed products. Variations in pulp properties such as fiber content, moisture content, and fiber distribution can result in inconsistencies in product density, dimensions, and mechanical properties. Consistent pulp quality helps maintain product quality standards and reduces the likelihood of rejected products.
Surface finish: The type of pulp and how the material is prepared as well as the quality of the pulp can impact the surface finish of the formed products, whereas high-quality pulp delivers a superior surface finish and appearance. Pulp with fine fibers and low levels of contaminants produces smooth and aesthetically pleasing surfaces, whereas coarse or contaminated pulp may result in rough textures or surface defects.
Yangi's Simplified Process: Minimizing the Need for Additional Materials
During our decade-long technology development at Yangi, we've engineered a process enabling us to fabricate pads with high network strength and even grammage weight distribution, eliminating the need for tissue addition, and supporting the structure. Though sometimes advantageous, the inclusion of tissue often presents certain challenges.
Firstly, incorporating tissue can increase production costs, potentially affecting product competitiveness since the introduction of tissue complicates the manufacturing process, requiring extra handling steps and potentially extending production time.
Also, ensuring compatibility between tissue and fibrous materials is challenging due to variations in their properties, potentially causing tissue delamination. Maintaining consistent quality is another concern, as differences in tissue properties may impact product performance and appearance.
Finally, environmental considerations are crucial, especially regarding non-renewable or non-biodegradable tissue sources, which raise ecological concerns and waste management challenges. Tissue use can in some cases improve product performance but may also have limitations, requiring thorough evaluation for suitability in specific applications.
The Transformation Journey of Fibers in Yangi’s Dry Forming Technology, Cellera
The formation of fibers in the dry forming (also known as dry molding) process is critical for achieving desired product characteristics and performance attributes. The quality of the fiber network imparts strength, stiffness, and dimensional stability to the final product. Through a complex interplay of fiber bonding, orientation, and consolidation mechanisms, we can enhance the final product’s quality and performance. Fiber orientation influences material properties such as network strength and formability, further expanding the versatility of dry-formed products.
Fiber formation in Yangi’s dry forming technology, Cellera occurs through several interrelated mechanisms:
Fiber separation: The raw material undergoes a milling process to separate the pulp into individual fibers without changing their structural properties, preparing them for airlaid formation technology. Utilizing a specialized air system engineered for optimal fiber formation, the separated fibers are then conveyed to the airlaid forming station. This technology enables the creation of high-quality cellulose-based packaging materials by ensuring uniform distribution and interlocking of fibers, resulting in enhanced network strength for improved shapeability.
Different fiber lengths cater to diverse product requirements; longer fibers enhance network strength for shaping, while shorter fibers suit shallow products. The fiber formation process is meticulously designed to ensure high-quality fiber separation throughout, from the milling stage to the formation drum.
Pad formation: - Yangi's Cellera dry forming technology employs a robust dual drum formation process that is designed to expedite the startup phase. By meticulously optimizing grammage distribution, this innovative approach enables the technology to swiftly achieve a stable operational state. The dual drum formation method generates discrete pad formations, minimizing waste and ensuring consistent grammage weight.
Also, the dual drum setup enhances quality by dividing the formation into two steps, reducing material per drum, and enabling individual design for optimized pad geometry and pulp properties. Manufacturers can tailor pad geometry and grammage to meet specific product requirements, with easy tooling modifications for quick adjustments.
Cellera's unique feature lies in forming discrete elements tailored to each pressed product's size, eliminating material interconnections between neighbouring products, and ultimately enhancing product formability. This streamlined process results in higher throughput, increased flexibility, and superior product quality. This approach minimizes trim waste and startup waste while maintaining excellent process control, resulting in low defect rates. The formed pads then undergo 3D shaping using unique technology, ensuring precise pad placement in the press for consistent results.
Product forming: The 3D pressing technology complements the airlaid forming process by applying pressure and heat to the cellulose fibers, transforming them into a durable and versatile packaging structure. Heat and pressure are applied to bind the fibers together and form the desired shape without the need to add any process water.
Fiber Bonding: Under pressure, fibers in the pad formation come into close contact, facilitating fiber bonding. This bonding can occur through mechanisms such as mechanical interlocking, chemical bonding and hydrogen bonding, depending on the nature of the material.
Fiber Orientation: As the product is formed, fibers in the pad undergo orientation in the load-carrying direction within the fiber network, leading to the alignment and the formation of fibrous structures. This orientation contributes to the mechanical properties of the final product, enhancing its strength and stiffness.
Deformation and Consolidation: The application of pressure induces deformation in the fiber network allowing for the consolidation of fibers into a cohesive structure. This consolidation process further promotes fiber-to-fiber interaction by reducing porosity and enhancing inter-fiber bonding.
Factors Influencing Product Formation
The size, shape, surface area, and shapeability of the fiber network significantly impact product formation.
Pressure & temperature: The magnitude and distribution of pressure, as well as the temperature and time during compaction, influences the degree of fiber bonding and densification as well as shape orientation and particle rearrangement. Optimal process parameters must be carefully controlled to achieve the desired mechanical properties of the final product.
Tooling Design: The design of the tooling cavity, including its geometry, surface texture, and release mechanisms, affects the distribution of pressure and the uniformity of fiber formation. Proper tooling design is essential for minimizing defects and ensuring consistent product quality.
Additives and Binders: The incorporation of additives or binders can modify the properties of the fibers, enhancing the packaging performance, such as barrier properties and strength. However, the selection and concentration of additives must be balanced to avoid compromising the integrity of the final product.
When it comes to the dry forming process, the choice of material is paramount, and our commitment to excellence shines through in every aspect of our machine design. By meticulously considering the material input, we ensure that our customers can deliver robust, high-quality, and consistent packaging products every time to their customers.
From increased production capacity to superior quality control, Yangi’s dry forming technology Cellera, was engineered to deliver unparalleled results, making it the clear choice for manufacturers seeking reliability and excellence.
With our dedication to maximizing material efficiency and output quality, choosing our machine isn't just a decision—it's a strategic investment in your success. Discover more about our complete solution for fiber-based packaging by contacting us today. Let's revolutionize your packaging process together.