Optimization of Fiber-Water Dispersion Process Using Box-Behnken Design of Experiments Coupled with Response Surface Methodology of Analysis

In this work, the fiber-water dispersion process with reference to the wet-lay technology was optimized in order to improve the uniformity of the wet-laid webs by using Box-Behnken design of experiments coupled with response surface methodology of analysis. A series of wet-laid webs were prepared by using cotton fibers of 7mm cut length and 5.6 micronaire linear density and employing different combinations of three process variables of interest namely stirring rate, dispersion time, and surfactant concentration. The resulting webs were tested for their area-based uniformity by means of quadrat analysis. The response surface model was found to be statistically significant at a P value as low as 0.0213. The experimental results were found to be in good agreement with the model results. The single effect of surfactant concentration, interaction effect of surfactant concentration and stirring rate, and quadratic effect of dispersion time were found to be statistically significant at 0.05 level of significance. The optimum level of coefficient of variation of the area occupied by the fibers in the web was predicted as 10.50% at stirring rate of 250 rpm, dispersion time of 5 minutes, and surfactant concentration of 0.10 and this was experimentally observed as 11.02%.