Airlaid Pilot Plant

Airlaid Pilot Plant OvenBased on the newest generation Dan-Web airlaid pilot plant machine, with two independently fed forming heads, this R&D system offers maximum grade flexibility.  Operating at relatively slow speeds compared to commercial production lines, this pilot plant can make novel structures for tomorrow's products today.  The plant can make unusually light or very heavy composite fabrics including those normally made on carding equipment.  100% synthetic fiber webs are possible at both high and low basis weights in uniformly blended composites or as layered webs.  

Marketing Technology Service, Inc. is pleased to offer the industry a complete pilot plant airlaid former, available at our testing facilities.  The plant includes a dual-head Dan-Web air forming machine, three synthetic fiber feeders, two pulp hammermills, an oversized AIRTHERM through-dryer and four-roll heated calender and offers:

  • Production of 0.25 m wide webs at basis weights from about 12 to 1500+ gsmAirlaid Pilot Plant Former
  • Handling of various virgin and recycled wood pulp fibers and all kinds of synthetics up to about 14 mm depending on the fiber used
  • Production of fiber/superabsorbent composite webs - latex, thermal or multi-bonded

This pilot facility is designed to make nonwoven, paper, paperboard, and exotic prototype blend test rolls for confidential client research.  Additional equipment and client-supplied components can be added to this layout on a contract basis.


Airlaid Pilot Plant Fiber FeedersMTS Airlaid Pilot Plant - General Specification

The airlaid process for making wood pulp fibers into roll goods has great potential.  Besides obvious environmental benefits, airlaid composite webs offer almost unlimited product development opportunities for both the paper and nonwovens industries.

Because MTS's laboratories have many years of experience with airlaid grade development and product testing, the new pilot line has been specially designed to offer maximum flexibility regarding recipes and basis weight.  Designed from the beginning as a "test roll" development facility, a great deal of prototyping can be performed without the expense associated with running full-scale machines for concept testing.  A full range of virgin and recycled fibers, particles and additives can be produced at ultrahigh or ultralow densities using latex, thermal bonding or water/pressure bonding techniques.

Basis Weight

  • One layer basis weight (wood pulp only measured with no latex or SAP) is 12 - 700 g/m2.  Fabrics containing SAP can achieve much higher single-pass basis weights
  • Two separate forming heads are available with fully independent pulp and synthetic fiber feeds, allowing complex multi-layer or homogenous webs
  • Multipass is also possible to build even more exotic layered fabrics and for high basis weights


  • 0.03 to about 0.3g/cm3
  • Compression rolls both before and after the dryer allow production of high bulk tissue-type webs or high density paperboard

Superabsorbent Addition

  • Homogeneous blends, tight center web SAP layers or center layer SAP mixed with fiber
  • Controllable layers with SAP injected in the center and fiber veneers on the outside
  • 0 - 90% granules, up to 100% possible with SAP fibers
  • The granular dosing and metering systems are adjustable for 3-dimensional control

Synthetic Fiber Blends

  • Synthetic fibers of most types can be handled and metered up to about 12mm in length
  • Multiple synthetic fiber metering systems allow complex blends and even 100% synthetic fiber webs

Pulp Defibration

  • Commercial Kamas H-12 hammermills and knife mill with two pulp unwinds processes 100mm wide fluff rolls with a full selection of screens and with capability of handling nondebonded pulp, non-roll waste paper, etc.

Bonding Methods

  • Latex spray bonding, calendar bonding or thermal bonding by through-dryer are all available
  • Electrically heated rolls can be used for compression or bonding
  • Latex and thermal bonding can be used alone together.  For very high basis weights an oversized through-dryer offers precise control and extra time-at-temperature capabilities
  • Wide temperature capability and very long time-at-temperature are possible
  • The extremely capable four-roll heated calendar includes air doctors for lightweights and can be configured for pattern bonding/embossing and densifying at moderate or extremely high

Terms for Typical Projects

  • US $4400/ 7 hour day
  • Raw materials are provided by the customer and returned at the end of the trial
  • Wrapping/palleting/shipping expenses are charged to the customer
  • Customers renting more than 10 days/year receive discounts, depending on volume
  • Customer pilot plant equipment can be installed on MTS's line and tested.  Cost is based on specifics of the project and duration
  • Contract laboratory testing of fabrics can be done on-site in our extensive testing lab, offering the most advanced testing equipment and skilled operators
  • Confidentiality is a proven commodity at MTS

Fiber Feeders Kamas Hammermill Kamas Hammermill Kamas Knife Mill Fluff Pulp Unwind Fluff Pulp Unwind Dan-Web Dual Head Former Dan-Web Dual Head Former Adjustible Suberabsorbent Doser Metering Chimney Former Dan-Web Dual Head Former Dan-Web Dual Head Former Adjustible Superabsorbent Doser Dan-Web Duel Head Former Latex Sprayer Airtherm Through Dryer Beloit Wheeler Calender Independent Machine WinderAirlaid Pilot Plant Schematic


Last Modified: May 6, 2003



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