1. “PCA” – Polyclean Applicator the patented application system
“ The Cost-effective, continuous keeping clean of Dryer Cylinders and Fabrics through Passivation“

2. Causes of deposits in the Drying Section
Sticky impurities / Stickies from the waste paper
Originally small particles accumulate on the dryer fabric and/or cylinders and build up
Fiber dust
Paper fibers are torn out of the paper surface as a result of the damp paper web adhering to the cylinder, leading to dust in the dryer section and contamination of cylinders.
Starch or coating particle deposits after a size press or coater, resin deposits

3. EXAMPLES

4. Deposits can lead to various problems
Possible effects
of deposits
Health & Safety
(increased hazard potential)
Quality problems/ Reclamations
Production problems
Subsequent problems in converting
Dust explosion/ fire hazard
Hazard potential from manual cleaning
Holes in the Paper
Dirt in the Paper
Poor moisture cross profile
Printability issues
Breaks
Waste
Reduced efficiency/ drying efficiency
Shutdowns
Breaks
Deposits
Waste

5. Treatment concept to prevent or reduce the contamination of the dryer fabric
Possible
methods
Prevent the formation of stickies in the system. (Mass treatment)
Clean the contaminated dryer fabrics.
Prevent material from the paper web from adhering to the dryer fabric.
(Passivation)
Which approach is chosen depends on the possible results which can be achieved, in comparison to the expenses / costs.

6. PCA is inserted into the doctor blade holder
What actually is a PCA and how does it work?
The PCA is a newly developed application unit which can be inserted into an existing doctor blade holder.
existing doctor blade is removed
PCA is inserted into the doctor blade holder

7. What actually is PCA and how does the application work?
The PCA applies Polyclean, a specially developed product, permanently and evenly across the width of the treated surface.
The resulting passivation of the surface means that:
Stickies no longer stick on the cylinder surface.
The adhesion of the wet paper web on the drying cylinder is considerably reduced. In this way, dusting and picking is significantly reduced and the plugging of the cylinder is prevented.

8. Passivation – the use of a light coat of a protective material to create a shell against corrosion (adhesion prevention).
A very thin layer of a special passivating agent is continuously applied to the surface to be treated.
The coated film prevents sticky substances or paper fibers from adhering to the treated surface and from being torn from the paper / cardboard, and accumulating on the surface of the drying fabric or drying cylinder.
The treated surface stays clean much longer or even permanently clean (depending on the degree of contamination before) and possibly cleaning can be reduced to a minimum or may be omitted.
In contrast to most cleaning processes, with passivation there is no risk of damage to the treated surface.

9. Application of the Passivation Agent
For the application of the passivation agent, a special application system had to be developed.
The main requirements for this system were:
A uniform, continuous application of a very thin film over the entire width
As few as possible moving or electrical parts? (The environmental conditions are not optimal for the stability of mechanically moving or electrical components)
Application to both the cylinder and to the dryer felt
No spraying (atomisation, blocking of nozzles etc.)
Small footprint (the space for the installation of additional equipment in the drying section is often of limited availability)

10. PCA Holding plate for insertion into bladeholder
Application wick with built in metering
Coupling piece for connection to product feed pipe

11. PCA+ (PCA W/ Blade holder)
For applications where in addition to the PCA, a doctor blade is still needed, and for which no double doctor system is present, the PCA+ was developed.
PCA
Blade holder
PCA
Loading hose for compressed air controlled loading of the PCA
Loading hose for compressed air controlled loading of the PCA
Holding plate for insertion into blade holder

12. PCA Dosing Unit Warning light
Control cabinet with possibility of connection to the PLS
Automatic air removal
Flow measurement and monitoring
Filter unit
Compressed air control for PCA+
Dosing pump

13. PCA is inserted into the existing doctor blade holder
PCA Installation
After the dosing unit has been previously installed, the PCA can be installed without the need for a shutdown. Only a short stop of the machine is required to install the PCA.
Existing doctor blade is removed
PCA is inserted into the existing doctor blade holder

14. PCA In Operation
PCA
Dosage pipe

15. Example of results of a cylinder treatment
without Polyclean
with Polyclean

16. Application examples Initial situation:
Passivation of a lead cylinder between press and drying section.
Initial situation:
lead cylinder with extreme build up
high dust level in the beginning of the drying section (every 2-3 hours a cleaning of the pan of the doctor blade holder is necessary)
the first 3 cylinders of the drying section are covered with fibers
Situation after installation of PCA:
cylinders are no longer covered with fibers and stickies
dusting in the drying section is eliminated

17. Application examples
Passivation of the first drying cylinder in the drying section
Initial situation:
drying cylinder extremely clogged
downtime due to breaks  2.4%
bad moisture cross profile
Situation after installation of PCA:
no more build up on the drying cylinder
downtime reduced to 0.7%
reduction of humidity regulation at the nozzle moisturizer from 0-100% to 0-70%

18. Application examples 3) Passivation of the first roll of a calendar
Initial situation:
breaks (on average 3 per shift) due to stickies, as a consequence more breakdowns and broke at the calendar
lots of stickies on the rolls and as a consequence holes in the paper web
Situation after installation of PCA:
no breaks and holes, as well as clearly reduced maintenance
reduction of expenses, set-up times of calendar rolls, and reduced grinding

19. Application examples 4) Passivation of dryer fabrics
Initial situation:
heavy plugging of dryer fabrics
significant reduction of the air permeability of the dryer fabric after short duration
very short dryer fabric lifetime
Situation after installation of PCA:
dryer fabrics and its guide rolls are clean
significantly better moisture cross profile of the paper
significant increase in dryer fabric lifetime

20. Summary of advantages of PCA application
smooth and clean surface of the treated cylinders, rolls and dryer fabrics
significant reduction of picking & dusting
increased lifetime of dryer fabrics
increasing of cylinder temperature is possible
less breaks
reduced efforts in cleaning and maintenance
possible increase of production capacity
reduced specific energy consumption
better moisture cross profile
.....

21. Advantages of PCA compared to traversing nozzle
less maintenance efforts
no spraying
compact construction size
permanent and even application across the complete width of the surface to be treated
no additional and troublesome components
no electrical drive
fewer moving parts
no investments or maintenance costs

22. Procedure when interested in using the PCA
Coldwater will review the situation on-site and discuss and document the possibilities of installation with you.
You will receive a quotation for the passivation product. When you are interested, an implementation appointment will be arranged.
The PCA and the specifically developed dosing system are provided to you free of charge for the duration of use and the application of our product.
Therefore, you do not bear any risk, as you do not cover any investment costs for the dosing equipment.

23. PCA – Polyclean Applicator the patented application system
Refernce List PCA xls
PCA – Polyclean Applicator the patented application system