A Science and Technology Publication

Volume 10, No. 2 Summer, 2001

Wet Process Drainage Effects of White Water Chemistryand Forming Wire Structures

Effects of Water On Processing and Properties ofThermally Bonded Cotton/Cellulose Acetate Nonwovens

Microstructural Analysis of Fiber Segments In Nonwoven FabricsUsing SEM and Image Processing

The Role of Structure On Mechanical Properties of Nonwoven Fabrics

Studies on the Process of Ultrasonic Bonding of Nonwovens:Part 1 Theoretical Analysis

Pira Abstracts ... Patent Review ... Researchers Notebook ... Technology Watch ... Directors Corner ... The Association Page

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Roger Chen

Joint INDA-TAPPI Conference

Please complete and return to INTC or fax to 919-233-1282.

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Major Merger!Big Success!At the request of theindustry, INDA andTAPPI combined theirtechnical conference toproduce the largestnonwovens technicalconference in the world.A total of 550 peoplefrom around the worldattended INTC-2000.

Leading EdgeInformation: Polymers & Fibers Properties & Performance Process Technologies Filtration End-uses Binders & Additives Wetlaid Absorbents Barriers Melt Extrusions Hydroentangling Airlaid Mats Biodegradable Polymers Sustainable Polymers Multi-component Fibers Microfibers Composites & Laminates State of the Art Information

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Research & Development

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INJ Spring 2001 1

A Science and Technology PublicationVol. 10, No. 2 Summer, 2001

PublisherTed WirtzPresidentINDA, Association of theNonwoven Fabrics Industry

SponsorsWayne GrossExecutive Director/COOTAPPI, Technical Association ofthe Pulp and Paper IndustryTeruo YoshimuraSecretary GeneralANIC, Asia Nonwoven FabricsIndustry Conference

EditorsRob Johnson856-256-1040rjnonwoven@aol.comD.K. Smith480-924-0813nonwoven@aol.com

Association EditorsCosmo Camelio, INDAD.V. Parikh, TAPPI Teruo Yoshimura, ANIC

Production EditorMichael JacobsenINDA Director of Publicationsmike@jacorpub.com

Wet Process Drainage Effects of White Water Chemistryand Forming Wire StructuresOriginal Paper by Daojie Dong, Owens Corning Science and Technology Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Effects of Water On Processing and Properties of Thermally BondedCotton/Cellulose Acetate NonwovensOriginal Paper by Xiao Gao, K.E. Duckett, G. Bhat and Haoming Ron, University of Tennessee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Microstructural Analysis of Fiber Segments In Nonwoven FabricsUsing SEM and Image ProcessingOriginal Paper by E. Ghassemieh, H.K. Versteeg and M. Acar, Wolfson Schoolof Mechanical and Manufacturing Engineering, Loughborough University . . 26The Role of Structure on Mechanical Properties of Nonwoven FabricsOriginal Paper by H.S. Kim and B. Pourdeyhimi, Nonwovens CooperativeResearch Center, College of Textiles, North Carolina State University . . . . . 32Studies on the Process of Ultrasonic Bonding of Nonwovens:Part 1 Theoretical AnalysisOriginal Paper by Zhentao Mao and Bhuvenesh Goswami, School of Textiles, Clemson University . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Guest Editorial 3Researchers Toolbox 4Directors Corner 7Technology Watch 10Nonwovens Web 12

Nonwovens Patents 48Worldwide Abstracts 53The Association Page 56Meetings 57

NonwovensI N T E R N A T I O N A L

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ORIGINAL PAPERS

The International Nonwovens Journal Mission: To publish the best peer reviewed research journal with broadappeal to the global nonwovens community that stimulates and fosters the advancement of nonwoven technology.

EDITORIAL ADVISORY BOARDCosmo Camelio INDARoy Broughton Auburn UniversityRobin Dent Albany InternationalEd Engle FibervisionsTushar Ghosh NCSUBhuvenesh Goswami ClemsonDale Grove Owens Corning

Frank Harris HDK IndustriesAlbert Hoyle Hoyle AssociatesMarshall Hutten Hollingsworth & VoseHyun Lim E.I. duPont de NemoursJoe Malik AQF TechnologiesAlan Meierhoefer Dexter NonwovensMichele Mlynar Rohm and HaasGraham Moore PIRA

D.V. Parikh U.S.D.A.S.R.R.C.Behnam Pourdeyhimi NCSUArt Sampson Polymer Group Inc.Robert Shambaugh Univ. of Oklahoma Ed Thomas BBA NonwovensAlbin Turbak RetiredLarry Wadsworth Univ. of TennesseeJ. Robert Wagner Consultant

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The International Nonwovens Journal is brought to you from

Associations from around the world. This critical technical publi-

cation is provided as a complimentary service to the membership

of the Associations that provided

the funding and hard work.

PUBLISHER

INDA, ASSOCIATION OF THE NONWOVEN FABRICS INDUSTRYTED WIRTZPRESIDENT

P.O. BOX 1288, CARY, NC 27511www.inda.org

SPONSOR

TAPPI, TECHNICAL ASSOCIATION OF THE PULP AND PAPER INDUSTRYWAYNE H GROSS

EXECUTIVE DIRECTOR/COOP.O. BOX 105113

ATLANTA, GA 30348-5113www.tappi.org

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Conventional wisdom suggests thatResearch and Development is essen-tial to the creation and ongoing success ofan industry as well as individual compa-nies within an industry. The nonwovenindustry is a prime example of the rolethat R&D has played in nonwovens brief

history of some60 years.

I have spentalmost 50 yearsassociated withnonwovens andhave had a ring-side seat in thedynamic growthof the business

from its infancy to a major business seg-ment. It is my intent to hit some of thehighlights of this growth with a specialemphasis on the role that R&D played.My use of the term R&D is in its broad-est sense, which includes process inven-tion, modification and control; productinvention and modification; and marketresearch and sales development. Perhapsnonwoven technology growth is a betterterm than R&D since I look at the wholechain of events as the end result of tech-nical development.

My introduction to nonwovens came atCallaway Mills, La Grange, GA, in 1953.I was happily involved in R&D with abroadly diversified textile firm when theboss called me to his office and informedme that We are going into nonwovensand you have the project. I knew nothingof nonwovens beyond the word, but with-in a year submitted a proposition toinstall a pilot line using Rando Webbersto produce industrial nonwoven fabrics. I

was then thrown out of R&D and trans-ferred to a production unit that grew tofour lines. Our plans centered on automo-tive products (backing for vinyl coat-ings), chaffer fabrics for tires, shoe find-ings and interlinings.

At this time in history, there were fouror five nonwoven producers in the coun-try (Pellon, Chicopee, and West Point-Pepperell being the major players); allwere using proprietary technologyinvented and modified for specific mar-kets. Total sales were around $5 million.Great secrecy surrounded the business.As Technical Director of a small produc-tion unit, I found that I had to invent theproduct, develop the process and then goout and sell the product since our indus-trial sales force was unable to handle thisnew product. In fact, we had to inventthe market and then invent the customers.

In 1960, I joined Kendall in Boston,which had been a pioneer in nonwovensfor over 20 years. Their output came fromthree proprietary lines making specialtyproducts for the electrical, graphic artsand dairy industries. A NonwovenDivision was formed in 1960 with totalsales of a little over $3 million! By 1970this new division was approaching$100 million in sales!

So what happened to make this sleepylittle business explode during the 1960sand 70s? Major new products wereinvented and marketed using nonwo-vens. Prime examples include: dispos-able diapers by P&G, followed by manyimitators; surgical packs and gowns plusa host of other hospital products fromKimberly-Clark, J&J, DuPont andKendall; and major new industrial fabric

markets created by DuPont and others.These new markets were a direct result

of a bewildering array of new technolo-gies introduced by companies both out-side and inside the textile industry. Itseemed that everyone was getting into theact! The paper industry introduced bothwet and dry nonwovens; Kimberly-Clarkbrought forth Kaycel and Kimlon.DuPont developed flash spun and spun-bond nonwovens, Monsanto developedchemical spun products, and Exxoninvented melt blown nonwovens. Itbecame obvious that hundreds of mil-lions of dollars were being spent bydiverse industries to get a piece of theburgeoning nonwovens industry. In 1968,we established a trade association(INDA) to encompass this wide array ofinterests to promote the business.

The slow, simple, inexpensive textileequipment that started the nonwovenbusiness underwent massive technicalinnovation to stay in the game in face ofthe assault from outside. In 1962, Kendallhelped P&G invent the disposable diapertopsheet. We used a 40-inch card linerunning 20 yards/minute. By 1964, wewere stretching a 40-inch card web to60 inches and running at 60 yards/min.By 1966, we stretched a 40-inch cardweb to 90 inches and ran at 90 yards/min.This stretched web was an innovationthat forecast the high-speed randomizingcards specifically designed for nonwo-vens. Today, reportedly, there are five-meter wide card lines capable of operat-ing speeds up to 1000 meters per minute!

Since I entered the industry, the non-wovens business in North America hasgrown from approximately $5 million tothe current $3.8 billion and 25.6 billionyards (INDA 2000 Estimates). Vast tech-nology changes have occurred.

So, is it all over? Of course not! Fiftyyears from now, the industry will be asdifferent and advanced from today astoday is from when I started in 1953.Leading the charge to make this happenwill be the hundreds of R&D people cur-rently working on nonwovens and thehundreds that will follow to keep the rev-olution going.

Have a nice journey! Wayne Hays

CONTINUE THEJOURNEYBy Wayne HaysFormer INDA Chairman and Recipient of theIDEA 01 Lifetime Achievement Award

GUEST EDITORIAL

INJ Summer 2001 3

Roger ChenReturn To Table of Contents

Useful Microwave TechnologyIn a few short years, the handy

microwave oven has become very ubiq-uitous (ubiquitous: adj, seeming to bepresent everywhere). In view of itsspeed, economy, efficiency and conve-nience, it is not too surprising that thistool has made its way out the kitcheninto a wide variety of other applica-tions.

The adaptation of microwave tech-nology to applications within the textileand nonwovens industries has beensomewhat slow and still rather limited.Through the efforts of several groups,however, this situation is changing, andthe microwave system is finding its wayinto numerous uses in the productionplant and also in the laboratory.

The first commercial use ofmicrowave heating for a textile dryingunit operation was probably the appli-cation to drying rayon filament yarnbobbins. In this application, the wet,freshly spun and washed filament bob-bin was placed on a conveyor that slow-ly passed through a zone of microwaveradiation. Each individual bobbin wasrotated on its axis as it slowly traversedits path through the drying zone.Bobbins of dry filament were removedfrom the unit.

The first use of a microwave systemin the laboratory was undoubtedly thedrying of small textile fabric samples asa part of the determination of moisturecontent. For this application, the speedand convenience were unparalleled byother methods. However, this methodand other similar trial efforts highlight-ed a major problem with the microwave

systems available uniformity of thetreatment. In the kitchen microwaveoven, the target is often on a turntable toprovide multiple passes in front of thesource to hopefully even out randomlyoccurring hotspots. Unless the treat-ment is done uniformly, hotspots candevelop, resulting in over-heating insome areas and under-heating in others.

To correct this problem, recent workhas focused on the use of waveguidesto serpentine the microwave energyback and forth across whatever materialis being treated. With proper design ofthe waveguides and supporting equip-ment, a specific environment for theparticular wavelengths can be created toprovide a controlled distribution of themicrowave energy, making it possible toachieve uniform exposure to any mater-ial moved though a channel or space. Insome designs, the waveguide itself actsas the treatment space and the position-ing (top, bottom, middle) of the materi-al as it travels through the space canprovide additional control over theenergy picked up by the material.

With this improved uniformity in dis-tribution, some amazing results can beachieved. Two different fabrics can bepassed through a carefully designedchannel or oven plenum, the one fabricentering wet and the other being dry. Onemerging, both of the fabrics are at anequal level of dryness, with no over-heating of the dry fabric. This is thetype of result that technologists havehoped for from microwave technology,and now it appears to be available.

One company that has been a leaderin this work is Industrial Microwave

Systems (IMS) of Morrisville, NC(IMS, 3000 Perimeter Park Drive,Morrisville, NC; 919-462-9200;www.industrialmicrowave.com). Theirpatented design concept is called thePlanar Drying System and it usesmicrowave energy focused at specificangles to achieve various treatment pos-sibilities. Some of their applicationshave involved treating tubular knits,sheets of individual yarns in yarn sizingapplications, and others. In a systemdesigned for terry towel drying, fasterproduction speeds were possible withthe uniform treatment. An additionalbenefit in this case was that the fabrichad good softness, even though a chem-ical fabric softener was not employed.

This method has also ben applied tothe drying of carpet tile. In this applica-tion, uniform drying can be achievedwithout damaging the backing or sub-strates, and there was no heat degrada-tion of the carpet material.Significantly, substantially increaseddrying speeds can also be achieved.Installations have been made up to 30-feet wide and material can be treated ina thickness up to two inches.

This company has recently becomeinvolved in several nonwoven applica-tions, one of which has been assisted bya grant from the federal Department ofEnergy, which is interested in the ener-gy saving possibilities with this type ofsystem. This has involved direct drying,drying of printed webs and coatedwebs, as well as treatment and drying ofcomposite and laminated structures.

The system has also been applied tothermosol dyeing; in this case the excel-lent uniformity has virtually eliminatedthe usual liquor migration in the treatedfabric, resulting in more uniform dyedistribution. With a suitable design,microwave drying in a dye beck or jetdyeing unit can be achieved with a tem-perature variation within the fabric ropeof only 0.10C.

The beauty of the microwave systemis the fact that the energy absorption canbe controlled to a rather fine degree.The oscillating microwave energy is notabsorbed to any degree by nonpolarmaterials. This includes most polymeric

RESEARCHERSTOOLBOX

INJ DEPARTMENTS

4 INJ Summer 2001

http://www.industrialmicrowave.com).http://www.industrialmicrowave.com).Roger ChenReturn to Table of Contents

http://www.industrialmicrowave.com).

INJ Summer 2001 5

materials and most fibers of interest tothe textile and nonwoven industries.The polar water molecules held within anonpolar matrix do absorb the energyvery efficiently, as they attempt to oscil-late in a synchronous manner to themicrowave oscillations. Because of thevelocity of the oscillations, the watermolecules become heated, putting themin an ideal condition to be evaporatedfrom the substrate.

As soon as the substrate has lost itswater content, no further absorption ofthe microwave energy occurs, and sothe substrate does not heat up, but canactually begin to cool. As a conse-quence, the energy absorption can bevery specific to water if the proper sys-tem is employed.

Other molecules in addition to waterwill absorb microwave radiation, soapplications beyond drying are alsopossible. Metals absorb energy from amicrowave source. This feature resultsin some limitations, but also in someunique applications. For example, finemetal powder can be suspended in aninactive medium, which is printed ontoa substrate. Only the printed pattern isheated as the substrate traverses a treat-ing system. Many other variations havebeen conceived for exploitation of thesystem.

Numerous laboratory uses formicrowave treatment are evolving andfinding utility in a variety of applica-tions. These will be discussed further ina subsequent issue of the InternationalNonwovens Journal.

Nonwoven Processing Equipment atTexas Tech

A frequently encountered problem innonwoven development work: A goodconcept needs further work and somepilot trials, but the necessary equipmentis not available!

One of the most effective solutions tothis dilemma is to seek the necessaryequipment elsewhere and to makearrangements to use the equipment on atemporary basis. In these circum-stances, the facilities at various univer-sities is often the answer. Such facilities

can generally be leased or otherwise bemade available on a fee basis. This canfrequently be accomplished, with theadded bonus that skilled operating per-

sonnel can also be obtained. When theright location is identified, this can bean elegant solution to the problem.

A few years ago, INDA organized a

RESEARCHERS TOOLBOX

PORTABLE SPECTROSCOPY OFFERS A SOLUTION TO AN AGE-OLD RESEARCH PROBLEM

Every now and then laboratory scientists are given a problem where theywished they could take their laboratory into the plant, the customers opera-tion, or some other remote location to study a particular situation. The scientisthas often been convinced that if only they could get the infrared unit or someother equipment into a particular location, the answer could be easily obtained.

A sizeable step forward in making that wish come true is the advent andadvances associated with portable spectroscopy units. Feature articles in thisDepartment in previous issues of the International Nonwovens Journal havedwelt with the advances being made in equipment to assist in identifying plasticmaterials slated for recycling efforts. Now, further powerful equipment and capa-bilities have advanced beyond, with the development of portable spectrometerswith broad capabilities and even portable FTIR equipment.

The Tristan line of spectroments typifies some of these advances. This partic-ular product line is the development of an alliance of three German companiesthat brought their specific talents together to develop this sophisticated system.The company m-u-t GmbH brings their engineering and development experienceon R&D operations to the alliance. Photon Technology International Inc (PTI)has broad experience in spectroscopy, as does PhotoMed GmbH, with specialskills in applications.

Together, the group has developed the portable and versatile Tristan unit, whichcan measure absorption, reflection, transmission and fluorescence by measuringthe wavelengths and intensities of light emission. It can rapidly and simultane-ously detect the entire spectral output of light from ultraviolet to the near infrared,along with an extended-red sensitive version. The unit includes the light sources,probes, sample handling accessories, optics system, computer for control andrecording of spectra. Developed applications include analysis of ingredients andraw materials, textile color control, identification of plastics, glass and other recy-clates. A power source allows eight hours of remote operation. (PhotonTechnology International, 1009 Lenox Drive, Suite 104, Lawrenceville, NJ08648; 609-896-0310; Fax: 609-896-0365; www.tristan-home.com)

Portable FTIR technology has been used for a wide variety of analyses, includ-ing organic chemicals, inorganic materials, clays, soils, paints and other coatingmaterials, petrochemicals, petroleum products, adhesives, plastics and others. Aninteresting application that has quite fully exploited the potential of this portableequipment is in connection with the examination of paintings, sculpture andother art objects.

In this case, the on-site capabilities, as well as the non-destructive characterand the adaptability to extremely small sample size have been significant advan-tages. This has allowed art conservators and experts to authenticate art objectsand also to eliminate fraud and counterfeit items. Further, this technique hasbeen very useful in examining deterioration and guiding restoration efforts. Oneadditional interesting use for portable FTIR has been in examining petroglyphson stone walls and in caves at some remote archeological sites.

Maybe that difficult problem out in the plant can be studied and solved withFTIR analysis after all.

http://www.tristan-home.com http://www.tristan-home.com http://www.tristan-home.com

survey of the nonwoven process andtesting equipment available at the majoruniversities in the US; a report of thefacilities available at that time was pre-pared. Material from this report is cur-rently available at www.inda.org.

With an announcement coming out ofTexas Tech, a new location and theirnew process equipment now needs to beadded to this roster. Texas TechUniversity in Lubbock, TX has recentlyadded some advanced needling equip-ment, which puts them in a potent posi-tion to become deeply involved in non-woven technology. This equipment isbeing added to the International TextileCenter at Texas Tech, under the direc-

tion of Dr. Seshadri Ramkumar, AdjunctProfessor at Texas Tech.

The Nonwoven Laboratory at theInternational Textile Center will be thefirst facility in the U.S. to have thisneedling capability. It is based on thestate-of-the-art Fehrer H1 Technologyneedlepunch loom. The principle of theH1 Technology and of this equipment isthe special properties that can beobtained by oblique angled needle pen-etration. This unique capability isachieved by means of an asymmetrical-ly curved needling zone, accompaniedby a straight needle movement. Becauseof this design, some fibers are punchedor inserted at an angle rather than in a

vertical direction. According to thedesign developer, the advantages of thisnew technology include the following:

1. The longer needle path results inbetter fiber orientation and fiber entan-glement than the conventional needlemachine.

2. Superior web properties can beobtained with fewer needle penetra-tions.

3. It greatly enhances the constructionof composite and hybrid products.

4. It delivers increased productivityversus conventional needlepunchlooms.

The processing line includes units forcomplete processing, from bale to fin-ished fabric. A Tatham Card fitted witha three-roller/seven-roller design is fedby a Tatham Single Automatic Feeder,Model 503; this latter unit is equippedwith a volumetric delivery system. AMicrofeed 2000 unit is included in theline to monitor the fiber delivery fromthe chute section of the volumetric hop-per and to speed of the card feed rollers;this compensates for any discrepancybetween the pre-programmed targetweight and the continuously monitoredactual weight. Thus, the Microfeedunit ensures extremely accurate fiberdelivery into the card unit. The webfrom the card is delivered from the sin-gle doffer section of the card to aTatham conventional design crosslap-per. The line is equipped with an ACInverter-controlled drive system.

A research program focusing on thisnew line has been supported by aresearch contract from the Soldier andBiological Chemical Command of theU.S. Department of Defense. The majorobjective of this research program is todevelop special protective fabrics thatcan be used by the Command to provideadvanced textile materials to all branchesof the military.

Additional information can be obtainedfrom Dr. Seshadri S. Ramkumar,Texas TechUniversity, International Textile Center, Box45019, Lubbock, TX 79409; 806-747-3790,ext. 518; Fax: 806-747-3796; s.ramku-mar@ttu.edu; www.itc.ttu.edu/ram.htm.

INJ

6 INJ Summer 2001

RESEARCHERS TOOLBOX

INTC 2001: A GREAT TOOL FOR BOTH THE INDA AND TAPPI TECHNICAL COMMUNITY

The 2nd Annual International Nonwovens Technical Conference(INTC) 2001, co-sponsored by TAPPI & INDA, will be heldSeptember 5-7, 2001 at the Renaissance Harborplace Hotel in Baltimore,Maryland. Over 80 technical papers will be presented in 14 sessions,making INTC 2001 one of the largest technical conferences ever in thenonwovens industry.

Combining the TAPPI Nonwovens and INDA technical conferenceshas worked out for the better of the technical nonwovens community. Oneexample is found in the Properties and Performance session. NormLifshutz will present results on the development of a fiber length testmethod conducted in a TAPPI Fiber Length task force, while MikeThomason will present INDA test methods on behalf of the INDA TestMethods Committee.

Other sessions of focus are: Absorbents, Barrier, Binders & Additives,Filtration, Finishes & Surfaces, Mats & Insulation, On-Line Measurements,Polymers & Fibers, Properties & Performances, Sustainability, and four ses-sions have been devoted to new process technologies.

INTC 2001 will once again offer attendees the nonwoven tutorialtaught by industry veterans, Roy Broughton, of Auburn University, TerryYoung, Procter & Gamble, and Alan Meierhoefer, Ahlstrom Fibers. Otherreturning favorites include the Student Paper session, the NewTechnologies Showcase and the evening tabletop event and reception.

The six technical committees of the TAPPI Nonwovens Division Properties and Performance, Process Technology, Building and IndustrialMat, Binders and Additives, Polymers and Fibers, and Filtration willmeet during the lunch sessions on September 5th and 6th.

Written papers are due to INDA by June 26 and presentations in elec-tronic form are due to TAPPI by August 1.

For conference or registration information regarding INTC 2001, visitINDAs website at www.inda.org or call 919-233-1210.

http://www.inda.org.mailto:s.ramku-mar@http://www.itc.ttu.edu/ram.htm.http://www.inda.orghttp://www.inda.org.mailto:s.ramkumar@ttu.eduhttp://www.itc.ttu.edu/ram.htm.http://www.inda.orgmailto:s.ramkumar@ttu.eduRoger ChenReturn to Table of Contents

http://www.inda.org.mailto:s.ramku-mar@http://www.itc.ttu.edu/ram.htm.http://www.inda.org

Success In Innovation ProjectsA research center within the Wharton

School of Business at the University ofPennsylvania focuses on innovation andentrepreneurship. The Sol C. SniderEntrepreneurial Research Center isstaffed with world-renown scholars andresearchers and has done some far-reaching research in the correlation ofinnovation with other business and eco-nomic factors.

A recent study was directed towardthe effects on innovation team perfor-mance of three underlying elements ofmanagement organization and opera-tion. The three elements studied indetail were as follows:

Task Structure: The physical organi-zation of the innovation team.

Project Framing: Delineation of theproject goals and methodology.

Team Deftness: Team effectivenessas assessed by past performance andother factors.

The study used a total of 138 innova-tion projects for analysis, projects inwhich the ultimate success and effec-tiveness could be quantified.

The results of this study suggestedthat the absence of Project Framing interms of clearly specified goals andresponsibilities had a negative correla-tion with team performance. Clearlydefined goals and clean-cut responsibil-ities are critically vital to the innovativesuccess of the team. Any uncertainly inthese two factors were manifestly oper-ative in detracting from the perfor-mance of the innovation team.

The factor of Team Deftness corre-lated with performance of the team, andalso had an impact on Project Framing.The researchers suggested that this fac-tor had a moderating effect on the totalperformance, and could help to modify

some of the problems associated withProject Framing. This suggested thatexperienced and capable innovatorscould overcome, to a certain extent, theshortcomings of management in notclearly defining the goals and teamassignments. In essence, the experi-enced innovators sensed the need andfilled this missing factor themselves.

The researchers concluded that theoften-assumed positive relationsbetween organization of the team andits success is valid, but only for relative-ly high levels of organization and oncomplex projects.

The message: Organize your teamwell; provide very clear-cut objectivesand responsibilities; and use capableand experienced people on your innova-tion team.

Attracting Laboratory TechniciansSome concerted thinking and action

is being devoted to the position of labo-ratory technician. In the past, many ofthe individuals who are lab technicianshave come into the laboratory withoutexperience; it often has been the respon-sibility of the employer to train suchindividuals and to equip them for theresponsibilities they will eventually begiven.

Such home-grown talent may havesufficed in the past. Certainly, someoutstanding people have come upthrough the ranks in this fashion. Morethan a few patents covering nonwoventechnologies have the name of an out-standing lab technician as a co-inventor.

However, training of laboratory tech-nicians is being done more and more bytrade schools, community colleges andeven universities. A capable lab techni-cian can be a real asset to a R&D estab-lishment. Consequently, more thought

is being given to the proper training anddevelopment of such talent. ThePartnership for the Advancement ofChemical Technology recently conduct-ed a Research Profile Study to assessthe personality traits, attitudes, learningstyles and values of quality lab techni-cians. The study, sponsored by theNational Science Foundation, coverednot only such individuals, but also stu-dents studying for such a career, as wellas instructors involved in their training.

The study found these individuals tobe highly collaborative and only moder-ately independent or competitive. Thestudents also tend to be more introvert-ed than the general class of students,and they are nontraditional, with manyolder than 30.

In focusing on the ideal instructionfor these individuals, the study revealedthat curriculum designers should con-sider including group problem-solvingactivities and roundtable discussions intheir courses for lab technicians. Theseare the skills and environmental fea-tures involved in this type of work, andso appropriate training should be pro-vided.

Also, the study showed that almosthalf of the technician students have afriend who works in a laboratory orsimilar job, suggesting that current labworkers are a good conduit for gettingthe word out to prospective students.Further, greater efforts should be madeto assure these students that the careersavailable put them in a good position totruly become professional researchers.

R&D Return On InvestmentA sizeable portion of the industries

throughout the world would considerthemselves to be a part of a vastresearch-driven enterprise. Certainlythose in the nonwovens industry wouldconsider their activities to fit into thisclassification. (Note the message in theeditorial in this issue.)

Such research-driven companiesalmost invariably believe or at least paylip service to the concept that moneyinvested in R&D activities provide apayback. Proof of such a return, howev-er, is always difficult to establish, espe-

DIRECTORSCORNER

INJ DEPARTMENTS

INJ Summer 2001 7

8 INJ Summer 2001

cially if inadequate accounting practicesare employed. Too frequently the evi-dence is ephemeral, a gut feeling, oranecdotal in nature. Many businessleaders want a more precise and defend-able basis for the annual agonizing deci-sions involved in approving the R&Dbudget.

Surely the $419 billion chemicalsindustry in the U.S. is a research-drivenaffair. And yet, even this business seg-ment struggles with the Return OnInvestment for the R&D budget.Noteworthy is the fact that the chemicalindustry portion of the total U.S. R&Dinvestment has been declining for years,from 11% in 1956 to about 8% in thepast decade.

The exact reason for this decline isuncertain; perhaps the percentages areskewed by the fact that the computerand related research-oriented industrieshave grown so much in the past decadeand chemicals are just a smaller piece ofthe whole. Undoubtedly another factoris that no one has exactly quantifiedwhat kind of bang these companies getfor their research buck.

A new report from the Council forChemical Research (CCR) addressesthis problem by analyzing data frommore than 80 publicly traded chemicalcompanies. From this study the conclu-sion was drawn that, on the average,every dollar invested in chemical R&Dtoday yields $2 in operating incomeover six years. This has apparently con-firmed many of those gut feelings.

In the next phase being pursued bythis program, CCR will evaluate resultsfrom specific types of R&D. It is hopedthis study will lead to techniques, topicsand evidence that will further validatethese concepts. This should materiallyhelp to further sharpen the businesscommunities view of R&D expenses inthe chemical industry. It is sincerelyhoped that similar forces are actingwithin the nonwovens industry.

Getting the Message OutOne of the most difficult responsibili-

ties for a Research Director is to get outthe numerous messages associated with

DIRECTORS CORNER

MEETING STAFFING NEEDS WITH SENIORS

Although conditions change quite rapidly, there does seem to be continuingproblems with research organizations filling all of their staff needs. TheResearch Administrator feels this is especially true when it comes to filling theempty slots with good people.

One potential source that may be overlooked in this search is the labor pool ofolder workers and even senior citizens. Of course, most of these slots requirespecial skills. However, such special skills are not unknown amongst the reser-voir of such older people.

Some universities have done an excellent job with this approach, enlisting theservices of experienced and seasoned professionals. Sometimes the position iscreated with a specific individual in mind, perhaps to teach a special course orassist with a special project. The position of Adjunct Professor, AdjunctResearch Scientist or similar is often used to designate and exploit such talent.There are several notable examples of this approach within academe at the pre-sent time, in both the practical as well as the theoretical domain.

However, virtually all levels of technical, scientific and business activities canbe considered for this approach. A second career, even at a lower level and asomewhat different arena, may be attractive to individuals with talent, skills andexperience. The old wisecrack about the person who retired and then went seek-ing a job after six weeks likely has a solid basis in fact.

This is borne out by data from the recent U.S. Census. The number ofAmericans 65 and older working or seeking work increased 10% between March1999 and March 2000 to 4.5 million, the Census Bureau said in a recent report.These data indicated that there was a 22% increase in seniors in administrativesupport positions, including clerical jobs, and an 18% increase in sales job.

The Alliance for Retired Americans, in pointing to these increases, indicatesthere are 32.6 million in the age group over 65, 1% more than in the previousyear. Not all of these people want to work, obviously, but an increasing portionapparently do want to continue to work.

It is interesting that a recent Wall Street Journal article (May 23, 2001)described an effort by the American Association of Retired People. This organi-zation wanted to select the Best employers for workers over 50. They mailedinvitations to 10,000 companies to provide information to assist in the selection.Only 14 companies responded!

Many companies indicated they had not given that aspect of their HumanResources efforts any consideration. It seemed to be an area where the averageemployer was largely out of step with the aging of the work force.

There are some companies that are exceptions, of course; they obviously areexceptional. At CVS drugstore chain, for example, 15% of the employees areover 55; CVS actively recruits older workers. It says they stay with the compa-ny longer and show more commitment.

There are obstacles to some of these practices, including phased-retirement,where an employee goes from a full-time status to employment that is less thanfull-time. Some of the obstacles are related to retirement, taxation, pension bene-fits, etc. These obstacles may require federal legislation to correct. Working con-ditions, flexibility and a desire for autonomy may be other factors to consider.

Overall, however, this is an employee pool that will receive more considera-tion by managers in the future. After all, during the year of 2001, the number ofworkers who are 40 and above will surpass those under 40 for the first time.Good Hunting!!

safety, accident prevention, pollutioncontrol and the like. It is a task that isnever finished; it has so many aspects,and yet can be critically important,especially in retrospect following anevent.

Pity the plight of the poor SafetyManager/Industrial Hygienist/Environ-mental Manager who must deal withsuch motivational things all the time.

The problem is to continuously getthe messages out to all personnel, getthem to read or study the materials atregular intervals, and then repeat andreinforce the messages unceasingly.Thats quite a challenge.

One enterprising Safety and Hygieneofficer within the Procter & Gambleorganization chose a rather unusualapproach that has proved to be quiteeffective. He acknowledges that he didnot get prior management approval forthe technique, undoubtedly because hewas rather confident that such approvalwould not be forthcoming. Neverthe-less, he moved ahead with determina-tion by regularly posting his safety mes-sages in the bathroom stalls at the P&GHealth Care Research Center in Mason,Ohio. To ensure sufficient time for theentire message to be read and studied,the postings were made adjacent to thetoilet commode, where they would beeasily available to every occupant.

The safety-related items were soonreferred to as potty postings, alsocalled toilet tabloids. The managerconfessed that there was a certainamount of resistance to the approach atfirst, but the message was getting out!One associate complained that Our lastbit of privacy is being invaded by safetymessages! Another asked the question,Is no place sacred?

Undaunted, Allan Bayless, the SafetyManager, persevered in the program andwas rewarded within a few weeks whenthe grousing subsided and some positivecomments began to emerge. He reportedthat some colleagues even began tooffer suggestions and to request newpostings if the current ones stayed uptoo long.

He now has management approval,

and reports that the approach is beingtried at other P&G locations. His expe-rience has shown that popular topicsinclude a range of rather violent events.Apparently everyone loves an accident,a flood, a fire or a reaction gone crazy.He always tries to exploit the describedevent by discussing what went wrongand what should be done to correct thesituation. Bayless found this approachto be much more effective than simplee-mailing individuals. After all, an e-mail can be discarded with a key stroke!

If this approach sounds useful andfurther information in desired, Baylesscan be contacted via e-mail atbayless.av@pg.com.

An Environmental PolicyThe peoples of this earth have come a

long way in developing an environmen-tal conscience and doing the rightthing. The past 40 years have seen alarge portion of the population growfrom disinterest into a strong concern forthe worlds environment and the legacythat will pass to future generations.

The effort has had its distracters ofcourse. On the one side there have beenthe adamant resisters and the obscenepolluters. On the other side have beenthe eco-extremists and eco-thugs.Despite this situation, progress has beenachieved.

An interesting policy statement on theenvironment and their relationship to ithas recently come from one of the non-woven industrys major members J.W. Suominen Oy, Nakkila, Finland.

While Suominens EnvironmentalPolicy statement is simple and straight-forward, it clearly provides a basis fordecisions both large and small. It can bereadily understood by top management,board members, middle managers andemployees at all levels, as well as bycustomers, competitors and the generalpublic. It would seem that all sectors ofthe industry would benefit from a simi-lar, simple statement or credo thatwould guide all phases of a companysoperations.

An example of SuominensEnvironmental Policy statement appears

in the box on this page. To decrease environmental loading,

JWS uses BATNEEC (Best AvailableTechnology Not Entailing ExcessiveCosts), minimizes the waste and recy-cles where feasible. JWS commits tofulfill relevant environmental legisla-tion, regulations and other obligations.

Top management establishes the envi-ronmental objectives and appropriateresources for their implementation andmonitors their performance.Supervisors are responsible for imple-mentation of environmental targetsrelated to their area of responsibility andcontinually aim to consider theimprovement of environmental perfor-mance while developing activities andworking practices.

Personnels commitment, as well asthe recognition of their own responsibil-ity, is ensured by systematic training,communication and encouragement.

While it may not be perfect, it is con-cise and understandable! INJ

INJ Summer 2001 9

DIRECTORS CORNER

ENVIRONMENTAL POLICYJ.W. Suominen develops, produces

and supplies nonwovens profitablyaccording to customers needs, such

that the activitys adverse environmen-tal impacts are as slight as possible.

JWSs key environmental aspects are:

Prevention of pollution.

Continual improvement so thatenvironmental loading, in relation to

production volume, decreases annually.

Environmental loading is moni-tored and measured comprehensively

and the results are public.

mailto:bayless.av@pg.com.mailto:bayless.av@pg.com.Roger ChenReturn to Table of Contents

mailto:bayless.av@pg.com.

Tracing Water Pollution SourcesIn the past, water polluters have benefit-

ted from the fact that water pollution can beclearly identified, but the source of pollu-tion is much more difficult. That situationmay be changing somewhat, with theadvent of a DNA fingerprinting test totrace the source of water pollution.

This test, which was developed at theUniversity of Missouri-Columbia, is basedon tracing the water pollution back to itssources by using the DNA from bacteria.The presence of fecal E. coli bacteria microbes that live in the intestines of theirhost until they are excreted commonlyis employed to establish if the pollution isdue to human or animal wastes. Whilethese organisms of themselves are non-pathogenic, their presence in a water givesa warning of the potential presence of otherdisease-producing strains of E. coli, salmo-nella or hepatitis virus that can also befound in human and animal waste.

The method utilizes a technique knownas DNA pattern recognition, or ribotyping.This novel approach takes advantage of thefact that each host species harbors specifictypes of E. coli in the intestinal tract thathave specific DNA patterns, or finger-prints. The DNA results are then com-pared to known DNA patterns from knownhost species. This then gives an indicationof possible sources of the contamination.

At the present time, the method can beused to clearly identify contaminationcoming from eight common hosts:humans, cows, pigs, horses, dogs, chick-ens, turkeys and migratory geese. Furtherwork is being carried out to expand theDNA database of hosts and to furtherrefine the technique to identifying charac-teristics of pollution sources. Currentchemical analysis, of course, can providevery precise information on the presence oforganic and inorganic pollutants; thesedates, coupled with water flow and move-ment patterns, can generally pinpoint thesources with convincing results.

Active AntibacterialsThe use of antibacterial agents in a host

of consumer, medical and industrial prod-ucts has exploded in the past few years.Seven times as many antibacterial prod-ucts were produced in 1998 than in 1992.Antibacterial finish has become the stan-dard finish in some textile product cate-gories. Nonwoven products have partici-pated in this action is a significant way,especially in nonwoven wipes.

The practice has become sufficientlywidespread that consideration has beengiven to legislation to stiffen controls onthe use of such materials. Some warningshave been put forth by the medical pro-fession, arising from the concern that suchmaterials can kill beneficial germs as wellas deleterious ones. Also, there is concernthat resistance to such agents can developand could lead to a range of super-germs.

Despite such concerns, the use of theseagents is proliferating.

Most such agents act by leaching fromthe material to which they are originallyapplied, and then contact the microorgan-isms and kill them by such contact. Theseare the leaching type agents.

Their effectiveness diminishes as theleaching continues, of course, and theleaching can lead to excessive skin con-tact or even to the crossing of the skin bar-rier; such behavior can lead to a variety ofproblems.

Another class of antibacterial agents isactually bound to the substrate by molec-ular or other forces. Such bound mate-rials usually have hydrophilic or othergroups in the molecule which can pene-trate the microorganism, allowing quater-nary ammonium groups or other groupsto rupture the organisms cell wall, lead-ing to expiration. This bound type ofmaterial can kill when the organismresides on the substrate; hence, it is morelimited in scope.

An interesting class of durable agentswas recently described with the added

feature of being capable of regenerationof the active chemical moiety. In thisagent, one functional group is used toattach the molecule permanently to cellu-lose fiber via a molecular bond. The func-tional group also contains a cyclic hydan-toin group, which can be easily chlorinat-ed to form the reactive cyclic chloro-hydantoin group. This latter group is aneffective disinfecting agent that is widelyused in swimming pools and other simi-lar applications. As the disinfectingaction continues, the chloro-group is con-verted back into the unsubstituted hydan-toin group. This latter group can be easi-ly converted back into the active chloro-hydantoin form; such chlorination can bedone simply by treating the fabric with achlorine bleach. Hence, the regenerablefeature.

Very recently a special polymer hasbeen developed at MassachusettsInstitute of Technology that is claimedto have special germicidal properties.When the polymer is coated onto a hardsurface, the developers claim that it isthere permanently and can guard againstinfections commonly spread by sneezesand dirty hands. The materials isdescribed as hexyl-PVP (PVP-polyvinylpyridine).

The PVP portion has been known to beactive in solution, but attempts to immo-bilize the material on a surface seemed torender the polymers totally inactive. Theresearchers found that the addition of thealkyl chain (3-6 carbon atoms) eliminatedthe inactivation. It is claimed that thismaterial in a coating form is able to kill upto 99% of Staphylococcus, Pseudomonas,and E. coli, all common disease-causingorganisms. The killing action is stated tobe via a powerful chemical-electricalaction. The researchers have hypothesizedthat the addition of the polymer side chainof the right length provides flexibility forthe coating material to penetrate the bac-terial cell wall envelope on contact and doits job. These are the first engineered sur-faces that have been shown to kill air-borne microbes in the absence of any liq-uid medium. This work suggests a newpossible approach to engineer a solid sur-face to provide bacteria-killing action.

The major markets for most types of

TECHNOLOGYWATCH

INJ DEPARTMENTS

10 INJ Summer 2001

INJ Summer 2001 11

biocides is for water treatment, paint pro-tection, wood preservation and similarapplications. Use in textile and fiber mate-rials is significant, however, and is contin-uing at a fast pace.

Another somewhat related develop-ment in chemical/biological activity oftextile fibers concerns cotton wipes thatcan be used to decontaminate nerveagents on contact. This work involvescovalently linking an enzyme to cottonfiber. The enzyme, organophosphorushydroxylase from Pseudomonas diminu-ta, is the only enzyme known to detoxifya wide range of nerve agents. The modi-fied fabric rapidly hydrolyzes the agentParaoxan (a nitrophenyl ester), indicatingthe immobilized enzyme retains it activi-ties. The fabric can also convert the infa-mous nerve gas, Sarin, along with others,as well as the toxic insecticides parathionand methylparathion, to harmless by-products. The fabric doesnt irritatehuman skin and retains 70% of its originalenzyme activity after two months, eitherrefrigerated or stored at room tempera-ture.

Modified fibers and fabrics can obvi-ously be made to do wondrous feats.

More Chemical ScaresA recent action by a government-spon-

sored panel of scientists and environmen-talists has the potential of creating a super-abundance of chemical scares in the future.If the course outlined by this panel is fol-lowing, research administrators are in for arough ride ahead.

The problem centers around a report bya National Toxicology Program panel,which concluded in May, 2001, that somechemicals can affect laboratory animals atvery low levels, well below the no effectlevels.

This rather shocking, self-contradictoryconclusion violates a fundamental princi-ple of toxicology namely that the dosemakes the poison. This principle assertsthat all substances can act as poisons in suf-ficiently high amounts, even such benignsubstances as water, sugar and salt; youname it. However, below their toxicdoses, such substances are considered notto be poisons.

The government panel concluded thatthere is credible evidence of the effect ofsome chemicals on laboratory animals atsuch very low levels. The evidence seemsto flow from concern with so-called

endocrine disruptors, also referred to asenvironmental estrogens. These materialsare described as hormone-like chemicals inthe environment that can disrupt normalhormonal processes and cause everythingfrom cancer to reproductive problems toattention-deficit disorder.

The public concern with these possi-bilities began with claims based onresearch work by the University ofMissouri researcher Frederick vom Saaland a book he published, entitled OurStolen Future. He carried out experi-ments on laboratory mice that purported-ly showed that very low doses of somechemicals increased prostrate weight inmale mice and advanced puberty infemale mice. The doses employed werethousands of times lower than currentsafe standards.

Reportedly, no other laboratory has beenable to reproduce vom Saals work; repro-ducibility of experiments is necessary, ofcourse, before a conclusion can be accept-ed. However, vom Saal all but guaranteedthat his work will never be reproduced. Hisexperiments involved a unique strain ofmice that he inbred in his laboratory forabout 20 years. When the mice stoppedproducing the results he wanted, he killedthem.

However, the results he promoted wereembraced by others who felt they matchedtheir environmental and political agenda.The panel given the assignment to assessthis situation was apparently loaded withsuch individuals.

In any event, the panel recommendedthat the EPA consider changing its guide-lines for assessing risk of reproductive anddevelopmental effects from chemicals.According to some experts this recom-mendation is likely to spread to othernational and international regulatory agen-cies.

The low-dose theory could put virtuallyevery industrial chemical and many con-sumer products at risk of being stringentlyregulated or banned without a scientificbasis. This development bears watching byanyone concerned with chemicals andproducts. Further information can beobtained at several websites, includingwww.junkscience.com. INJ

TECHNOLOGY WATCH

SYNTHETIC PAPER SHOWING EXCEPTIONAL GROWTH

Originally introduced into Japan several years ago, synthetic paper is startingto show exceptional growth in a variety of markets and applications. This product consists of thin plastic sheet material containing a filler or a spe-

cial coating to give it the printing characteristics of conventional paper. The basefor a synthetic paper may be polyethylene, polypropylene, polystyrene or poly-ethylene terephthalate; suitable fillers are titanium dioxide, calcium carbonate orvarious silicas. typical paper coatings based on clay, calcium carbonate or othermaterials can be employed to provide a good printing surface.

The growth of this type of material is expected to be in excess of 8% per year,from a current base of about $200 million; this will result in a 166 million poundmarket by the year 2005, according to one recent study.

The use in specialty label applications is the largest current market for thesematerials. However, it is anticipated that growth in other related markets willexceed the growth in labels; these other market applications include commercialprinted products, such as greeting cards, menus, maps, books and covers, signageand point-of-purchase displays. In the label market segment, significant applica-tions include pressure sensitive labels, in-mold labels, and unsupported tags.

At the present time major producers include: PPG, Oji Paper (Japan) throughtheir subsidiary Yupo, Nan Ya Plastics, ExxonMobil, and Arjobex (a three-wayjoint venture of BP, Arjo Wiggins (London), and Appleton Papers). Some ofthese properties and markets suggest possible usage of nonwoven materials.

http://www.junkscience.com.http://www.junkscience.com.Roger ChenReturn to Table of Contents

http://www.junkscience.com.

Distance LearningIt used to be that a remote location pre-

cluded a number of activities for a per-son who was so unfortunate. An oppor-tunity to study and continue ones educa-tion was certainly one of those factorsthat had to be sacrificed. No More!!!

If the men and women serving in theU.S. Navy aboard a ship at sea anywherein the world can continue their graduateeducation, location is no longer an insur-mountable barrier. The solution is whatis referred to as Distance Learning.That is not learning about how far faris, but rather it signifies learning that canbe done at virtually any distance fromthe source of the teaching.

A growing number of universities andcolleges are beginning to offer anexpanding selection of courses that arepresented via the Internet. This arrange-ment is not the same as a correspondencecourse, as the student can virtually bepresent in the usual class setting andhave direct and instantaneous contactwith the instructor and fellow students,all by means of a computer terminal anda communications link.

Many universities are working to con-vert their classroom materials into a formmost suitable for this medium.Professors and teachers are learning howthe usual teaching methods can be mosteffectively converted into the cyberspaceclassroom. Some adaptation of methodsand materials must be made, of course,but the transition is being mastered.

At the government level, the SmallBusiness Administration (SBA) hasintroduced the new SBA Small BusinessClassroom, which brings electronic busi-ness courses to anyone with a standardInternet connection. This virtual class-room provides interactive, easily accessi-ble courses on the topics most in demandby small-business owners. Typical class-

es include: The Business Plan (inEnglish and Spanish) or How to RaiseCapital For a Small Business. At the endof each lesson, students can participate ina scheduled chat room, or call a toll-freenumber to talk with a counselor(www.sba.gov and then select SBAClassroom).

Not a part of Distance Learning, therewere recent press reports on several cam-puses involving enterprising studentsputting todays lecture notes on the webfor the benefit of friends who missed theclass. Some professors objected strenu-ously to this practice, even claiming thatnotes from their lectures were akin tocopyrighted material. In direct contrastto that attitude is the recent announce-ment by Massachusetts Institute ofTechnology (MIT) that over the next 10years, the university will post materialsfor almost all of its courses on the WorldWide Web, accessible to one and all at nocharge. Materials posted will include

course outlines, reading lists, lecturenotes and assignments.

As ambitious as this approach is (esti-mated cost is $10 million per year), it isprobably not the same as getting an MITeducation for free. Unlike DistanceLearning programs, which involve regu-lar exchanges between faculty and stu-dents, there will be no course credit ordegrees offered to people who accessOpen-CourseWare, as it is being called.

Nevertheless, the early response to theMIT move has been very positive. Notonly in developing countries, but inadvanced nations as well the benefits ofDistance Learning are being appreciatedand used. This activity will undoubtedlyfurther increase concern with theDigital Divide, which separates thosewho do not have access to the Internetfrom those who do.

Some professional societies arebecoming involved in the process. TheSociety of Dyers and Colourists in theUK has presented a Distance Learningmodule on Principles of Engineeringand Coloration Theory. Future planscall for additional modules on ColorPhysics, Colorant and PolymerChemistry, Coloration Technology, andOrganization and Management.

Within the nonwoven technology sec-tor some steps in this direction have been

THE NONWOVENWEB

INJ DEPARTMENTS

12 INJ Summer 2001

SPAM VS. spam

Even a novice on the Internet is familiar with the junk E-mail that virtuallyabounds on the net and goes under the name of spam. Such unsolicitedmail is a fact of life on the Internet and it is a rare netizen who hasnt experiencedit.

On the other hand, there is a well-known spiced lunch meat made of porkshoulders and ham that is known worldwide, and considered a choice delicacy inmany parts of the world. This product of Hormel Foods Corporation goes by abrand name that is considered a very valuable piece of intellectual property SPAM registered trade mark for the meat product.

For several years Hormel fought against the use of the word spam to desig-nate the wrong kind of e-mail. They worked diligently to protect their name andto police the mounting misuses. After this valiant effort, the company has final-ly acquiesced to a compromise, as outlined on their official SPAM website(www.spam.com/ci/ci-in.html). Hormel says it no longer objects to that otherdesignation, as long as it is spelled in small letters spam, that is. However, forthis concession, they expect their trademarked product to be spelled in capitalletters SPAM brand of meat product.

Seems like a reasonable compromise.

http://www.sba.govhttp://www.spam.com/ci/ci-in.html).http://www.sba.govhttp://www.spam.com/ci/ci-in.html).http://www.sba.govhttp://www.spam.com/ci/ci-in.html).

INJ Summer 2001 13

made and more are being taken. Accessto specific nonwoven technology trainingis becoming available from some univer-sities. Problems still exist, such as thematter of oversight and quality control,as expressed by some committees withinvarious universities. Also, there is thequestion of the more subtle interactionsbetween student and teacher which natu-rally arise from questions and answers,and by other means.

However, as more experience isgained, the processes will undoubtedlyimprove. After all, a telephone call to acolleague can be a form of DistanceLearning.

Electronic SignaturesThe electronic signature law went into

effect in June of 2000. This law givesdigitally signed documents the samelegal weight as those with physical sig-natures. In essence, this allows a personto simply click a box and accomplish thesame results as signing a document withpen and ink.

It may come as no surprise, however,to learn that individuals and companieshave been slow to stamp their signatureon business transactions via electronicmeans. Even with companies that coulduse this method to a great extent, such asfinancial services and legal firms, therehas been a reluctance to use the method.

One roadblock to the acceptance ofelectronic signatures is obviously theproblem with the ability to verify thesigners identity in court. It is rather dif-ficult for an individual to deny a signa-ture when it is there in ink on a docu-ment; it is considerably easier to deny itwhen done by an electronic keystroke,especially if there was no one around atthe time.

There have been attempts to useadvanced technology to eliminate thisfactor, and companies are offering secu-rity means to eliminate this uncertainty.Unfortunately, these means are ratherexpensive, especially for a single or onlya few signatures.

Where there are repetitive transactionsbetween two companies that have a con-tinuing relationship, or transactions with-

in a small, closed trading community, theconcept may be very viable.

Some of these problems are very simi-lar to those encountered on the Internet,where a great deal of effort has beenexpended to establish secure boundariesaround business transactions. Anonymityis an inherent feature of the net and elec-tronic space. This characteristic isacceptable for some interactions, but cer-tainly not for others. For now, most com-panies are taking a wait-and-see atti-tude toward the electronic signature.

Sci/Tech Web Awards 2001One of the very interesting websites on

the Internet is that of the science journal,Scientific American (www.scientifi-camerican.com). The site provides aTable of Contents of current and pastissues, and even posts the full text ofsome of the articles.

The publication also conducts an annu-al search of scientific sites and selectsfive sites from 10 different categories toreceive their Sci/Tech Web Award2001. The sites are selected for a varietyof reasons, as the selections are aneclectic mix from the practical to theacademic to the downright silly.

The categories covered by their searchinclude Archaeology and Paleontology;Earth and Environment; Astronomy andAstrophysics; Engineering andTechnology; Biology; Mathematics;Chemistry; Medicine; ComputerScience; and Physics

Some very interesting websites arisefrom the list of their selections. There isa site that gives a listing of a vast numberof acronyms, listed alphabetically or bytopic, along with definitions for thou-sands of the most current IT-relatedwords (www.whatis.com). The medicalcategory has an online version of theclassic reference book, Grays Anatomy,with 1,247 engravings from the original1918 publication (www.bartleby.com).The Engineering and Technology catego-ry offers an interesting web page thathighlights bad product designs resultingin items that are hard to use because theydo not follow human factors principles(www.baddesigns.com ).

The variety in the sites selected for theaward gives an appreciation of the diver-sity of material that is posted on the web.

Computer VirusesA new version of the computer virus

has struck the Internet. This recent virus,called sulfnbk, doesnt do much harmto your system, but it sends you on a wildgoose chase to find and eradicate anobscure and innocuous utility file (sulfn-bk.exe) in Windows 98/Me before a sup-posed expiration/explosion date.

When dealing with such matters, it isvery helpful to be able to call on someexpert advice and help. Again, theInternet comes up with the answer. Onesource of such assistance is a computerinformation resource (www.geek.com).This site has a variety of useful informa-tion, including a consumer warning areathat can be of real help in a situation ofthis type.

Also, another site can be a usefulresource when it comes to computervirus myths, hoaxes, urban legends, hys-teria and such. This site(www.vmyths.com) is dedicated to pro-viding the truth about computer virusmyths and hoaxes. This site includesinformation on new viruses as well as oldones, as it points out that Old hoaxesnever die, they just get a new life cycle.

Relatively New StuffThis phrase is the byword for a website

that is an online marketplace for used anddiscounted scientific equipment. The site(www.einsteinsgarage.com) offers usedand still-in-the-box, brand-name instru-ments, equipment, supplies, chemicals,safety apparatus, protective clothing,teaching aids and more. Their motto isThe theory of relatively new stuff, atake-off from the original Einstein.

The items offered cover a range ofproducts from well-known equipmentmanufacturers. They are offered on anauction basis, although users can sell,auction and advertise surplus equip-ment as well. Einsteinsgarage is amember of Alchematrix, a whollyowned e-commerce subsidiary ofFisher Scientific. INJ

THE NONWOVEN WEB

http://www.whatis.com).http://www.bartleby.com).http://www.baddesigns.comhttp://www.geek.com).http://www.vmyths.com http://www.einsteinsgarage.com http://www.whatis.com).http://www.bartleby.com).http://www.baddesigns.comhttp://www.geek.com).http://www.vmyths.com http://www.einsteinsgarage.com Roger ChenReturn to Table of Contents

http://www.whatis.com).http://www.bartleby.com).http://www.baddesigns.comhttp://www.geek.com).http://www.vmyths.com http://www.einsteinsgarage.com

AbstractThis paper reports the effects of white water characteristics

and forming wire parameters on wet process drainage. Byemploying a recently developed lab tester, the present investi-gation conducted drainage experiments of long (32 mm)fiberglass in polyacrylamide (PAM)-based white water with areal (commercial) forming fabric in position. The formingwires under investigation cover air permeability from 465 to715 CFM and drainage index from 9.5 to 22.

Drainage experiments show that both PAM concentrationand shearing (mixing) effect can strongly affect wet processdrainage. So, white water of fixed composition, but with a dif-ferent mixing history may behave very differently, and anincrease in input mixing energy usually results in a substantialincrease in drainage.

Mat basis weight also strongly influences wet processdrainage. Although an increase in basis weight always reducesthe rate of drainage regardless of wire structure, its impact ismuch stronger on the wires with a high air permeability and alow drainage index than the ones with a low air permeabilityand a high drainage index.

Another important finding of this study was that drainageindex did not predict the performance of a forming wire, andthe main causes were believed to be the fundamental differ-ences between the wet-formed glass mat (WFGM) andpapermaking processes. Also, correlation between air per-meability and wet process drainage was found very complex:while air permeability may be used as an empirical parame-ter to predict drainage for light weight mats at low PAM con-centrations, however, the higher the web basis weight and thehigher the PAM concentration, the more likely it would fail.

Key Words

Wet process, drainage, forming wire, drainage index, airpermeability, polyacrylamide, basis weight, shearing effect

IntroductionDrainage is one of the critical process variables in a wet

process (the wet-formed glass mat process or the WFGMprocess). Wet process uses higher viscosity white water andoperates at low slurry consistencies. Its drainage operation isusually more challenging than in a typical papermakingprocess, which is the primary reason that an inclined delta for-mer, instead of a Fourdrinier machine, is normally used in awet process to dewater fiberglass slurries.

Wet process drainage is a complex process depending onboth the physical characteristics of a fiber slurry and thedetailed structure of a forming fabric. The slurry characteris-tics encompass fiber content, fiber length and diameter, andwhite water chemistry, etc. The wire parameters may includeat least air permeability and drainage index, etc. Sincedrainage has great influence on both the sheet properties [1-4]and the mill performance, the paper industry has consistentlydevoted a great deal of resources to gain fundamental under-standings in this area [5-12]. Several experimental methods [6,13, 14] have been developed to measure the drainage, or free-ness, of papermaking furnishes, among which the CanadianStandard Freeness (CSF) test [14] is the most common one.

Though various lab drainage testers have been successfullyused to characterize the drainage characteristics of papermak-ing furnishes, they are generally not applicable to the fiber-glass slurries used in a wet process [15]. It is also worth not-ing that these lab drainage testers are limited to estimate onlythe drainage characteristics of furnishes and are not capable ofevaluating the effects of forming wire parameters [15]. In real-ity, a drainage process is controlled by the combination ofwhite water characteristics and the parameters of a formingfabric. Therefore, it would be very important to measure thedrainage rate under the combined conditions of all these para-

Wet Process Drainage Effects ofWhite Water Chemistry andForming Wire StructuresBy Daojie Dong*, Senior Scientist, Owens Corning Science & Technology Center,Granville, OH 43023

ORIGINAL PAPER/PEER-REVIEWED

14 INJ Summer 2001

* The author is currently a Senior Engineer with Decillion,LLC, Granville, Ohio

INJ Summer 2001 15

meters.Recently, a wet process mimic device (WPMD) has been

developed at the Owens Corning Science and TechnologyCenter that is capable of measuring the drainage rate of wetprocess slurries with real (commercial) forming fabrics inposition. The detailed information about the WPMD structureand developmental work can be found elsewhere [15].

In the present investigation, the WPMD was used as a toolto study the effects of both fiberglass slurry characteristics andforming wire parameters on wet process drainage. The rate ofdrainage was measured under a simulated line speed and cor-related to various parameters, such as, PAM concentration ofwhite water, mixing effect, web basis weight, fabric air per-meability and wire drainage index. The approaches used werevery practical, and the reported results are expected to haveclose correlation to real wet process operations. Theoreticalmodeling of the drainage process is out of the scope of thispaper, but might be addressed in the future.

ExperimentalApparatus

Drainage experiments were carried out using a wet processmimic device (WPMD) as shown in Figure 1. The detailedstructure and operation procedures of the WPMD were report-ed elsewhere [15]. Briefly, the WPMD consists of three stain-less steel chambers and two functional blocks, the drainagefunctional block (DFB) and the fiber bleed-through functionalblock (FBTFB). As shown in Figure 1, the three chambers arevertically arranged to create a gravitational flow field. TheDFB block is positioned in between the top and middle cham-bers, while the FBTFB block connects the middle and bottomchambers together.

The DFB, the heart of this tester, is primarily composed of(1) a gate (or shut-ter), (2) a piece of20 X 20 inch (51X 51 cm) formingfabric mounted ona holder, (3) amovable formingbed (MFB) con-sisting of a seriesof supporting bars,(4) a driving andcontrol system thatcontrols the move-ment and speed ofthe MFB, and (5) aflow control sys-tem that providesinitial settings fordrainage experi-ments.With forming wireA (as defined inTable 1) in posi-tion, the reported

WPMD has a maximum pure water drainage rate of about 145gallons per minute per square foot of forming area (gpm/ft2) ina gravitational field. In the present work, drainage experimentswere not carried out at its maximum capability. Instead, a setof parameters on the WPMD were chosen so that wire A pro-vided a pure water drainage rate of ~85 gpm/ft2. The rest ofexperiments were all conducted under these fixed conditions.

Forming WiresAs reported earlier [15], one of the special features of this

WPMD lies in its capabilities of measuring drainage rate usingreal (commercial) forming fabrics. In the present study, threecommercial forming wires were selected (from three differentsuppliers) and some of the wire parameters were summarizedin Table 1. These wires have similar structures and all fall inthe double layer category. But, their meshes, strand diametersand weaving patterns are very different from each other.

In Table 1, the fiber support index (FSI) and caliper data wereobtained from respective wire manufacturers. The AP(s) andthe DI(s) are the specified air permeability in cubic feet perminute per square foot (CFM) and the specified drainage index,respectively. The wire samples were measured for air perme-ability at the Owens Corning Science and Technology Centerbefore testing and the results were 715, 630 and 465CFM forwires A, B and C, respectively. Due to the changes in air per-meability value, the corresponding drainage indexes wererecalculated as 9.5, 17.8 and 21.1, respectively. In the section ofResults and Discussion, the measured air permeability (AP)and the recalculated drainage index (DI), the data in the last tworows of Table 1, were used to correlate to drainage.

To study the effect of wire parameters on drainage rate, 20X 20 inch wire samples were installed into the DFB block fordrainage testing, and all the comparisons were made underidentical experimental conditions.

MaterialsDrainage experiments were conducted with Owens Corning

786M 1.25 inch fiber, Cytec Superfloc A1885, and Rhone-Poulenc Rhodameen VP-532 SPB. The 786M is a chemicallysized fiberglass with a mean diameter of 16 microns. TheSuperfloc A1885 is an anionic, high molecular weight poly-acrylamide (PAM) and functions as a viscosity modifier. The

Figure 1WET PROCESS MIMIC DEVICE

Table 1FORMING WIRE SPECIFICATIONS

Wire ID A B CMesh (top) 56 X 26 65 X 52 107 X 54Mesh (bottom) 65 X 38 107 X 28Layers 2 2.5 2.5Caliper (inches) 0.080 0.075 0.0435FSI 36.0 48.4 86.0AP(s) (CFM) 750 660 490DI(s) 10.0 18.6 22.2AP (CFM) 715 630 465DI 9.5 17.8 21.1

Rhodameen VP-532 SPB is an ethoxylated fatty amine, a sur-face active molecule, and functions as a dispersant. In addi-tion, a small amount of defoamer was also used to controlfoam and assist the experiments.

DrainageIt is known that the PAM viscosity modifier is sensitive to a

shearing effect. The received PAM was first diluted to 0.5wt.% and agitated for 30 minutes. The same batch of dilutedPAM was used for the entire experimental work to avoid pos-sible variations in raw material and in dilution procedure.

The drainage volume was fixed as 20 gallons (of pure water,or white water, or fiber slurry). For white water (withoutfibers) testing, 20 gallons of water was fed into the top cham-ber, followed by a predetermined amount of PAM and 5 dropsof defoamer. The formulated white water was then agitatedunder specified experimental conditions before drainage.

A two step procedure, similar to a thick-thin stock proce-dure, was used in the preparation of fiberglass slurries. First,10 gallons of water were charged into the top chamber, fol-lowed by 10 drops of dispersant and 5 drops of defoamer.Then, the mixer (agitator) was turned on and a pre-weighedamount of fiberglass was added immediately. In the mean-time, a timer was started to record mixing time. After oneminute of mixing, a predetermined amount of PAM wasadded, and additional water was fed to make up a total volumeof 20 gallons.

While the slurry (or white water) being prepared, the movableforming bed (MFB) was set in motion at a desired speed, andother drainage parameters were also set at desired values. Whenthe slurry was ready for testing, the gate (or shutter) was openedinstantly and the drainage process began. The time duration ofdrainage was recorded and the average drainage rate was calcu-lated based on the known parameters of the WPMD. In thiswork, a unit of gallons per minute per square foot forming area(gpm/ft2) was selected for the rate of drainage.

A dual-propeller mixer driven by an air motor wasemployed for agitation. The mixer was positioned at the cen-ter of the chamber with its lower and higher propellers 2 3/8(6 cm) and 11 5/8 (29.5 cm) above the top surface of theforming fabric. The mixing (shearing) effect was controlled bythe inlet pressure of compressed air to the air motor.

ViscosityWhite water viscosity was measured with a Brookfield

Model DV-II+ viscometer.

Results and DiscussionPAM Effect

Figure 2 shows the influence of polyacrylamide concentra-tion on the drainage of white water (without fibers). All thewhite waters used in Figure 2 were mixed for 5 minutes witha compressed air setting of 28 psig. So, PAM concentrationwas the only variable, which ranged from 0 to 165 ppm with0 representing pure water.

As indicated in Figure 2, the presence of PAM significantlyreduced the rate of drainage. For wires A and B, the drainage

rate of pure water was ~83 gpm/ft2, and the presence of 66 and165 ppm PAM has reduced the drainage rate by ~35% and55%, respectively. For wire C, the presence of 66 and 165 ppmPAM has reduced the drainage rate of pure water by ~50% and74%, respectively.

The presence of PAM also significantly reduced thedrainage rate of fiberglass slurries as shown in Figure 3. Thenine data points used in the figure had a same consistency of0.012%, and each slurry was agitated for 5 minutes with apressure setting of 28 psig on the driving air motor.

Interestingly, the three wires responded similarly to the changesin PAM concentration. The drainage rate dropped sharply whenthe PAM concentration was increased from 10 to 65 ppm. As thePAM concentration was further raised to 165 ppm, the drainagerate continued decreasing, but with a much lower slope.

Basis Weight

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Figure 2EFFECT OF PAM CONCENTRATION ON

WHITE WATER DRAINAGE

Figure 3EFFECT OF PAM CONCENTRATION ON

FIBERGLASS SLURRY DRAINAGE

INJ Summer 2001 17

Gravity drainage, in essence, is a filtration process with thepressure defined by the gravity head of suspension over aformed web [9] supported on the forming wire. It is obviousthat the web thickness and its degree of compression willaffect the rate of drainage. Since the primary focus of thispaper is to deal with the practical aspects of drainage in wetprocess, the web effect on drainage rate was treated withrespect to mat basis weight in pounds per hundred square feet(pounds/CSF).

Three consistency values of 0.008%, 0.012% and 0.018%were purposely designed to study the web effect on drainagerate. These values, based on the particular parameters of theWPMD, correspond to the formed webs with fiber basisweight of 0.81, 1.30 and 1.86 pounds per hundred square feet(pounds/CSF), respectively. If a 19% of loss on ignition (LOI),a typical number for fiberglass roofing mats, is also accountedfor, the three consistency values would correspond to the fin-ished wet process mats with basis weight of 1.00, 1.60 and2.30 pounds/CSF. In Figures 4 and 5, drainage rate was plot-ted with respect to mat basis weight for the convenience ofreaders in the nonwovens industry. The fiberglass slurries usedin Figure 4 were all prepared at a fixed PAM concentration of165 ppm, and in Figure 5 at a fixed PAM concentration of 66ppm.

As indicated in Figures 4 and. 5, the rate of drainage wasreduced as the basis weight was increased from 1.0 to 1.60 and2.30 pounds/CSF. However, the degrees of change were dif-ferent among the three wires. For example, at a fixed PAMconcentration of 165 ppm (Figure 4), the drainage line forwire A has the highest slope, the line for wire B is less steep,and the line for wire C has the lowest slope. As a result, wireB has reached comparable drainage rates to wire A at basisweights above 1.60 pounds/CSF, though its rate of drainagewas ~20% lower than wire A at a basis weight of 1.0pounds/CSF. Figure 4 also indicated that the difference indrainage rate between wire C and the others was gradually

reduced as the increase in mat basis weight.At a fixed PAM concentration of 66 ppm (Figure 5), the

same trend seemed to hold. Wires A and B had similardrainage rates at all three basis weights. Wire C, again, neverreached comparable drainage rates to wires A and B, thoughthe difference was gradually reduced as the basis weight wasincreased.

Shearing (Mixing) EffectFigures 6 and 7 show that the PAM-based white water was

very sensitive to shearing (mixing) effect. All the slurries usedin the two figures had exactly the same composition: 165 ppmof PAM, ~2 ppm dispersant, ~1 ppm defoamer and a fiberglassconsistency of 0.012%. The variations in drainage rate werecaused solely by different shearing (mixing) history. In Figure6, all the slurries were prepared with a fixed mixing time of 5minutes, but, mixing pressure on the air motor was variedfrom 14 to 60 psig. In Figure 7, all the slurries were preparedwith a fixed mixing pressure of 40 psig, but mixing time wasvaried from 5 to 200 minutes.

Figure 6 indicates that, as mixing pressure was increasedfrom 14 to 60 psig, the viscosity of white water was reducedslightly (from 2.5 to 2.24 cps, ~10% reduction), however, therate of drainage was increased by ~70%. Both wires A and Bresponded to the shearing effect similarly.

At a fixed mixing pressure of 40 psig, as illustrated inFigure 7, the prolonged mixing dramatically increased the rateof drainage. As the mixing time was extended from 5 to 30,67, and 200 minutes, the rate of drainage was increased by~90%, 130% and 220%, respectively. In the meantime, thewhite water viscosity was reduced from 2.29 to 2.20, 2.05 and1.78 cps, respectively.

In Figure 8, all the data points in Figures 6 and 7 were com-bined and replotted against the viscosity of white water. Itclearly indicates that the two sets of data (from Figures 6 and7) followed a similar trend with respect to the white water vis-

Figure 4EFFECT OF BASIS WEIGHT ON DRAINAGE RATE

(PAM = 165 PPM, DISPERSANT = 2 PPM,AND DEFOAMER = 1 PPM)

Figure 5EFFECT OF BASIS WEIGHT ON DRAINAGE RATE

(PAM = 66 PPM, DISPERSANT = 2 PPM,AND DEFOAMER = 1 PPM)

cosity. The two wires A and B, again, responded similarly tothe mixing effect. The results in Figure 8 indicated that thestrong mixing (shearing) effect has broken the PAM molecu-lar structures, resulting in a reduction in flow resistance.

Forming Wire and DrainageAs mentioned earlier, wet process drainage is a filtration

process and depends on both the characteristics of white waterchemistry and the structures of a forming fabric. In the paperindustry, air permeability (AP) and drainage index (DI) are thetwo parameters that are believed closely related to thedrainage performance of a forming fabric. Air permeability isan experimentally determined value that measures the air flowrate in cubic feet per minute (CFM) per square foot of fabric.

Drainage index, as defined in Eqn. 1, is a calculated value [16,17] that takes into account for both the structural parametersand air permeability of a forming fabric.

Where, AP is the air permeability in cubic feet per

minute (CFM) per square foot, Nc is the CD (cross or trans-verse direction) mesh count, and b, as defined in Eqn. 2, is theCD support factor on the sheet side.

Although drainage index is usually believed to be a more

accurate prediction for the drainage capability of a formingfabric on a paper mill, there have been only a few reports [16,17] that correlated the rate of drainage to drainage index. Onthe other hand, there have been no known reports thataddressed how drainage index and air permeability of a form-ing fabric affect the rate of drainage in a WFGM process. Thefollowing discussion would provide some interesting results.

Air PermeabilityFigure 9 is a plot of drainage rate versus the wire air per-

meability under various experimental conditions. The resultsshown in Figure 9 included pure water, white waters with dif-ferent PAM concentrations, and fiberglass slurries at variousconsistencies. The legend water stands for pure water; theWW for white water with the last three digits representingthe PAM concentration in parts per million; and the X-Y fora fiberglass slurry in white water, in which the first number, X,represents the mat basis weight and the second number, Y, thePAM concentration in parts per million. For instance, the leg-end WW033 represents a white water with a PAM concen-tration of 33 ppm, and the legend 1.60-165 stands for a

18 INJ Summer 2001

Figure 6EFFECT OF MIXING PRESSURE ON DRAINAGE.

(CONSISTENCY 0.012%, PAM 165 PPM,DISPERSANT 2 PPM, DEFOAMER 1 PPM,

MIXING TIME 5 MIN.)

Figure 8DRAINAGE RATE VERSUS WHITE WATER VISCOSITY

(CONSISTENCY 0.012%, PAM 165 PPM,DISPERSANT 2 PPM, DEFOAMER 1 PPM)

Figure 7EFFECT OF MIXING TIME ON DRAINAGE.

(CONSISTENCY 0.012%, PAM 165 PPM,DISPERSANT 2PPM, DEFOAMER 1 PPM,

MIXING PRESSURE 40PSI)

(1)

(2)

INJ Summer 2001 19

fiberglass slurry that has a PAM concentration of 165 ppm andwould form a mat of 1.60 pounds/CSF after being dewatered.

Figure 9 indicates that for pure water and the white watersat various PAM concentrations, air permeability was a goodprediction for the rate of drainage. The drainage line for purewater and the four lines for white waters (WW