Duroblade: much more than just precision blade technology
BTG’s ceramic-tipped blades continue to win hordes of new converts worldwide, but productivity improvements don’t stop at the blade edge. BTG offers a range of state-of-the-art services to ensure customers always get the very best out of their creping installations.
BTG has earned worldwide renown as the inventor and manufacturer of Duroblade®, the original high-performance ceramic-tipped doctor blade, and CBC™ creping blade holder, the only equipment that allows for independent adjustment of blade sliding angle and linear load while running.
But the company’s creping expertise extends a whole lot further than just manufacturing. Through a comprehensive portfolio of value-added services including blade analyses, machine surveys, blade holder surveys, process trials and optimized cost and productivity calculations, we’re helping customers around the world boost their productivity.
Blade analysis
FIGURE 2
Cross-section of a ceramic-tipped blade
FIGURE 1
Abnormal tip wear of one meter of the blade, on the machine front side
Since Duroblade became the market leader in high-performance blade solutions, the need to optimize blade tip configuration to meet customer requirements saw blade analysis quickly become a core BTG competency. A BTG blade analysis delivers fast, accurate blade wear diagnostics, to give you a clear and accurate picture of your blade performance.
Using cutting-edge tools and technologies, our team of blade specialists provide unrivalled levels of investigation and evaluation, delivered via a full range of analytical services:
- Worn blade analysis report: a detailed investigation of blade tip appearance, wear identification and angle and surface measurements, via a digital blade cross-sectional study. Provides a full wear diagnosis, complete with illustrations, and recommends new blades or corrective actions.
- Blade wear profile analysis: provides a clear view of the profiles of worn active surfaces via a precise graph. Rapid identification of blade application irregularity allows for optimization of blade holder alignment in coating spray profile and Yankee conditions.
- In-depth blade tip research: a comprehensive analysis of wear patterns, combining surface characterization study and SEM exploration.
Machine survey
A personalized machine survey is an important part of blade trial preparation, providing key basic information about the creping conditions on the tissue machine.
The main aim of the survey is to identify factors related to blades, the blade holder and the Yankee that could be critical when using high-performance ceramic blades. Based on the results, our team provides detailed recommendations or a full action plan covering the necessary corrections, rebuilds or optimization measures.
BTG’s full machine survey package includes:
- A report on blade holder influence and Yankee surface material and condition, including a review of organic coating chemicals and add-on rates, and the design and performance of spraying equipment
- A detailed screening of the key work parameters and adjustment of the creping/cleaning blade to match core quality and productivity requirements
- Evaluation and proposals to reduce or minimize possible vibrations, dust and edge contamination
- A general review of the machine, process conditions and inputs.
CBC blade holder survey
Performed annually – or immediately after a Yankee regrind – BTG’s blade holder survey ensures the perfect functioning of your CBC creping blade holder. Our CBC team is available on call, and offers:
- Correct blade holder alignment to ensure suitable actuator expansion and even linear load along the blade length
- Synchronization adjustment of the blade contact angle, so that the sliding angle is the same across the machine
- Detailed analysis of the condition of pressure arms and actuators, and recommendations if replacements are required
- Thorough cleaning of all moving parts, along with the slot for the creping blade
- Recommendations for further optimization and/or training as needed.
Our team will also suggest the latest CBC upgrades if they’ll help improve performance. In our experience, combining Duroblade with CBC consistently pays off in terms of better performance, longer blade operation and increased productivity.
Technical trial support
Short test or long-term trial? In both cases, BTG has the tools and competencies needed to deliver in-depth analysis of blade performance to ensure you get top results and efficiency from your equipment:
- A trial preparation phase coordinated by a local BTG expert, featuring design of trial blades to match your unique machine conditions
- The presence of a BTG engineer for the duration of the trial, providing expert support and advice designed to optimize your process
- A Trial Report, correlating the trial plan and conditions with the results, and providing a general evaluation along with proposals for adjustment or further blade solutions as needed.
Cost and productivity calculations
Duroblade high-performance blades offer customers a wide range of technical advantages, enhanced by on-the-ground support from BTG experts worldwide. Delivering substantial savings through improved paper surface quality, greater production stability and reduction of machine stoppages due to blade changes, Duroblade is an excellent way of raising your productivity.
A quick glance at the simple Return on Investment (ROI) calculation below should be compelling enough to convince any remaining skeptic:
In addition, BTG maintains an active collaboration with other key suppliers to the industry, such as specialists in chemicals or Yankee metallization. One example is our partnership with Bender Machine Services Ltd, a leader in the surface metal spraying of Yankee and MG cylinders offering a range of solutions matched to each client’s specific application (see www.bendermachine.com). This working relationship out in the field means added value for our customers, who benefit from the combination of Infinikote® and Duroblade products as well as from the know-how of two dynamic and innovative companies.
To learn more about how much you can save by running high-performance blades, and how BTG can help you raise your productivity, visit www.btg.com or contact your local BTG representative.