Project Overview

Customer: Leading manufacturer of specialty paper and engineered fibre products

Location: Gloucestershire, UK

Application: Production of teabag paper

Equipment: Spooner Air Flotation Dryer

Original Installation: 1994

Issue: Product touchdown, unstable web handling and concerns over dryer performance

Background

A leading manufacturer of specialty paper and engineered fibre products operates an established Spooner Air Flotation Dryer within one of its UK manufacturing facilities.

Originally installed in 1994, the dryer is used in the production of teabag paper, a demanding application where consistent web handling and controlled drying are essential to maintaining product quality and production efficiency.

Following many years of operation, the customer began experiencing issues with product touchdown and flotation performance. Given the age of the equipment and the importance of maintaining reliable production, the customer asked SpoonerPlus to inspect the dryer and identify the cause of the problems.

SpoonerPlus has extensive experience in servicing, refurbishing, modifying and optimising existing Spooner equipment, with engineers combining process knowledge with detailed knowledge of the original machine design.

SpoonerPlus can also provide comprehensive refurbishment services for non-Spooner OEM equipment, helping customers extend the life and performance of their existing machinery. Our expertise allows us to assess, refurbish and restore equipment from a range of manufacturers to the required operational standards.

The Challenge

Following an initial inspection, SpoonerPlus engineers identified that the dryer nozzles had become worn, damaged and out of alignment.

Over time, nozzle wear and misalignment can affect the carefully controlled airflow required to support and transport the paper web through the dryer.

In this application, this was contributing to:

• Unstable web handling and product touchdown, creating a risk of contact between the web and dryer surfaces.
• Reduced flotation performance due to deterioration of the nozzle condition and alignment.
• The potential for creases and other product defects if the web became unstable.
• Increased cleaning requirements where contact or deposits occurred.
• The need for operators to compensate for poor web stability through changes to operating conditions, including increased airflow.
• Concerns over energy consumption and dryer efficiency.

The customer was particularly keen to understand whether restoring the condition and performance of the dryer could also contribute to reducing energy consumption and provide an acceptable payback on the proposed investment.

The Spooner Solution

After presenting the inspection findings to the customer and engaging in discussions around their expectations, SpoonerPlus recommended replacing the damaged and worn nozzles and restoring the correct geometry of the flotation system.

The proposed refurbishment included the supply of 26 new Spooner Airfloat Nozzles, comprising:

• 20 standard airfloat nozzles
• 4 anti-overspill nozzles
• 2 dampered airfloat nozzles

All replacement nozzles were specified in grade 304 stainless steel, complete with seals, mounting brackets and fixings.

SpoonerPlus also included levelling and alignment of the dryer to the entry and exit rolls, together with levelling and alignment of all nozzles.

This approach addressed both the condition of the components and the overall alignment of the flotation system, replacing parts that had deteriorated through long-term service while ensuring the system was correctly positioned.

The objective was to restore the intended airflow profile through the dryer, providing improved support and stability to the paper web and reducing the need for operators to compensate for poor flotation performance.

From an energy perspective, restoring the nozzle condition and alignment was intended to help the dryer operate closer to its original design performance. Improved airflow distribution can support more effective heat transfer, while improved web stability can reduce the requirement for additional airflow or other compensatory operating measures.

Importantly, the project provided a targeted refurbishment of the existing dryer rather than requiring replacement of the complete system, allowing the customer to address specific areas of deterioration while retaining an established production asset.

The Result

The project provided the customer with a targeted solution to the flotation problems identified during the SpoonerPlus inspection.

By replacing the damaged nozzles and restoring the correct level and alignment of the dryer and flotation system, SpoonerPlus addressed the underlying mechanical condition affecting web handling.

The refurbishment was designed to deliver:

• Improved web flotation and stability
• Reduced risk of product touchdown and web contact
• More consistent airflow across the drying process
• Reduced requirement for operators to compensate for unstable web handling
• Improved reliability of the existing Spooner dryer
• Support for more efficient dryer operation and energy management

Extension of the useful service life of a dryer originally installed more than 30 years earlier

For the customer, the project demonstrated how a focused SpoonerPlus refurbishment can help restore the performance of established Spooner equipment without replacing the complete machine.

The work also highlights the potential value of inspecting critical dryer components as part of ongoing equipment maintenance. In this case, relatively small components, such as the flotation nozzles, had a direct influence on web behaviour and the way the dryer was being operated. By combining component replacement with specialist inspection, levelling and alignment, SpoonerPlus was able to provide a targeted intervention aimed at improving process performance and operational efficiency.

To find out more about our Air Flotation Dryers or our dedicated refurbishment, upgrades and service support, please contact our experienced team here or call +44 (0)1943 609 505.

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