Foam Processing of Fibers As a Sustainable Alternative to Wet-Laying: Fiber Web Properties and Cause-Effect Relations

Wet-laying is a mature technology that is applied in large scale for the manufacture of nonwovens, including paper products. However, it usually uses large volumes of water and is energy-intensive. Here we used foam-laying to substantially diminish the volume of water consumed in the formation of fiber networks (5-fold reduction) and to reduce the water content of the nonwovens produced before drying, achieving a reduced energy demand. The prospects of foam-laying were evaluated by comparing foam-laid and wet-laid webs of two types of wood fibers: stiff (lignin-containing) or flexible (lignin-free). Also, the effect of foaming agent type (anionic, cationic, nonionic, and amphoteric) was elucidated. Reference webs were produced by conventional wet-laying, with or without surfactants. Foam-laying was effective in producing a more uniform areal mass distribution (better formation) after wet-pressing. This effect was more evident for the webs synthesized with the flexible fibers. Unlike the layered network st...