Forming Fabric with More Layers Do Not Always Mean Better

For many paper mills, when selecting or replacing the forming fabric, they often believe that the latest types of products (such as SSB forming fabric) are the best choice, due to their better performance in high-speed paper machines, especially in terms of abrasion resistance, stability, dewatering performance, fiber support, retention, and superior paper forming performance.

So, a common view is that directly selecting the best forming fabric can extend service life and improve performance.

But in actual paper production, more layers don’t mean they can perform better on your paper machine.

For forming fabric, the truly affecting factor about paper web performance and fabric lifespan is not the number of layers, but whether the forming fabric you purchase matches the operating conditions of your paper machine.​

Why Triple Layer Forming Fabric is Not Always the Best Choice

Undeniably, the triple layer forming fabric provides finer paper sheet support and improves paper surface quality. However, this structural advantage also means it places higher demands on the paper machine. 

Compared with single layer and 2.5 layer designs, triple layer forming fabric feature a more complex internal structure. If the paper machine cannot provide sufficient cleaning capacity, fibers, fillers, and fine contaminants are more likely to accumulate within the fabric, eventually reducing its permeability and drainage performance.

If the paper machine has sufficiently high-pressure spraying capacity, a stable vacuum system, and good cleaning conditions, these deposits can be washed away in time, with limited impact on operation.

Cleaning May Become a Challenge

But this is not the case for many old papermaking machines that are still in operation.

According to the age of the paper machine, issues like decreased high-pressure spray pressure, nozzle clogging, and reduced vacuum box efficiency, etc, will all affect the online cleaning performance of the forming fabric on the paper machine forming section. 

So, once you install the three layer forming fabric on the paper machine, internal deposits may not be able to be discharged in time, gradually causing mesh clogging.

Under this situation, the air permeability, dehydration efficiency, and vacuum load of the forming fabric will be decreased, and unstable paper forming will occur later. 

Choose the Right Forming Fabric

But if you choose the 2.5 layer forming fabric, it can be adapted to the cleaning capabilities of your paper machine. It can both provide better dimensional stability and significantly improve the retention rate of fine fibers.

So, for many paper machines, choosing a forming fabric with a structure more suitable for the equipment’s operating conditions is often more important than simply pursuing a higher number of layers.

Layer Count Is Only One Factor in Forming Fabric Performance

In addition to the layer, a high-quality forming fabric also depends on many other details in the manufacturing process of the fabric supplier.

It’s actually correct that although two formed meshes have the same number of layers, their actual operating performance may differ significantly due to the different production capabilities of their manufacturers.

Weaving Uniformity of Forming Fabric

Whether the tension of the warp and weft yarns remains consistent during the weaving process directly affects the structural uniformity of the entire forming fabric. 

If there are significant differences in tension in certain areas, the air permeability and dehydration capacity at different locations may deviate, thus affecting the moisture distribution across the web and the quality of the paper sheet formation.

Heat Setting Process

Stable heat setting can ensure the stability of the forming fabric’s size, reduce elongation during operation, and help maintain a stable operating state over a long period of time.

Transportation Methods

One crucial factor often overlooked is the transportation method of the formed mesh.

Forming fabric is a large, precision mesh and may experience rough handling, such as pulling during transport.

If the forming fabric is subjected to localized compression, folding, or impact from sharp objects during this process, permanent deformation of the fabric may occur. Pulling and other transportation methods may also cause edge abrasion of the mesh. All of these affect its operational stability after installation.

So, a professional supplier typically pays attention to packaging details.

Sun Hong uses multiple layers of surplus forming fabric to wrap products during transportation, with particular emphasis on protecting edges and joints to reduce the risk of damage during transit.

While these measures do not alter the structural design of the forming fabric, they ensure that the product arrives in optimal condition.