Airlaid Latex Binder Make-Up & Drying Load

The formula

This is the expression the tool evaluates. Every term is named underneath, with the unit it must be supplied in.

How the result is derived

Step by step, from the values you type to the figure on screen.

1. The 8 inputs are read from the form on every keystroke: Unbonded Web, Target Dry Add-On, Sides Sprayed, Emulsion Solids, Application Efficiency, Binder Cost, Dry Solids, Web Width and Line Speed.
2. Each value is checked against the accepted range in the input table below. A value outside its range stops the calculation rather than producing a misleading figure — the results blank out and a message appears.
3. The validated values are substituted into the expression above, which resolves Wet Spray Required together with every supporting figure in one pass — no value is carried over from a previous entry.
4. The supporting outputs — Dry Binder on the Web, Dry Binder Applied, Wet Spray per Side, Water to Evaporate, Bonded Basis Weight, Binder Share of Finished Weight, Wet Binder Consumed, Binder Lost to Overspray and Binder Cost — come from the same pass, so they always describe the same case as the headline figure.
5. Results are rounded for display only. The full-precision value is used throughout the chain, so reading a rounded intermediate figure back into the tool by hand can shift the last digit.

What each input means

Where to read each value on the floor, the unit it must be in, and the range the tool accepts.

What the tool returns

The headline figure and every supporting value it is built from.

Worked example

The tool loads with this case already solved — the Wet Spray Required shown above is its answer. Change one value and the difference from this baseline is the sensitivity of the result to that variable.

How to use it

1. Work through the input groups in order — Web & Target, Binder & Application and Line. The defaults are a realistic case, so you can change one value at a time and watch what moves.
2. There is no calculate button. Every figure recalculates as you type or drag, which is what makes this usable for a what-if sweep rather than a single answer.
3. Read Wet Spray Required in the dark results panel — that is the headline figure, expressed in g/m2.
4. Check the supporting rows underneath (Dry Binder on the Web, Dry Binder Applied, Wet Spray per Side, Water to Evaporate, Bonded Basis Weight, Binder Share of Finished Weight, Wet Binder Consumed, Binder Lost to Overspray and Binder Cost) before acting on the headline — they are where an implausible input usually shows itself first.
5. Reset to defaults returns every field to the reference case, which is the quickest way to check whether a surprising result came from the tool or from an input you had changed earlier.

Where this is used

• Process planning — establishing Wet Spray Required before a trial is booked, so machine time and material in Nonwovens, Filtration, Hygiene & Technical Webs are committed against a calculated figure rather than an estimate.
• Costing and quotation — Wet Spray Required is an input to the cost sheet, and quoting from a worked number rather than a remembered one is what keeps a margin intact.
• Troubleshooting — when the floor result drifts from plan, entering the measured values (starting with Unbonded Web) shows how much of the gap in Wet Spray Required each variable explains.
• Teaching and study — the accepted ranges bracket normal Nonwovens, Filtration, Hygiene & Technical Webs practice, so moving one variable at a time shows the shape of the relationship rather than a single answer.

Assumptions and limits

• Add-on is quoted on unbonded web weight here, which is the convention in airlaid; a specification written on FINISHED weight means something different by the same percentage and the two diverge quickly at high loadings - at 22 percent on web the binder is only 18 percent of the bonded sheet. Check which basis a customer specification is using before matching a number to it. Application efficiency covers overspray, misting and binder that penetrates through and is lost to the wire, and it is a machine-and-recipe property rather than a constant: it falls as viscosity drops, as line speed rises and as the web gets more open, so a figure measured on one grade does not transfer to a lighter one. The water figure is what the drying section actually has to remove and is usually the real capacity limit on an airlaid line - a grade change that raises add-on by five points raises the drying load far more than it raises the binder bill, and a line that runs out of oven before it runs out of anything else has this calculation to thank. Nothing here predicts bonded strength, which depends on binder glass transition, cure and fibre-to-fibre bond geometry rather than on quantity alone.
• Every input is bounded to the range normal practice occupies (Unbonded Web 10 to 600 g/m2, Target Dry Add-On 2 to 60 % and Sides Sprayed 1 to 2 nos, and so on for the rest). Those bounds are guard rails against typing errors, not a claim that the formula fails one unit outside them.
• The calculation is deterministic: the same inputs always give the same result. It carries no allowance for machine condition, operator skill, ambient conditions or lot-to-lot material variation unless an input above explicitly represents one.
• Nothing is sent anywhere. The maths runs in your browser, so the numbers you type never leave the page.

Questions people ask