Document 2qN93BkXN6Zme0vaVEgDXEevR
DOW CHEMICAL U.S.A
March 31, 1932
George Dusty Bird & Son, Inc. Washington Street East Walpole, MA 02032
P. O. BOX 1847 2040 OOW CENTER MIDLAND. MICHIGAN 48640
Dear Mr. Dusty:
It was a pleasure discussing Dow's composite paper technology with you. As a follow up to our conversation I have attached calculations displaying cost comparisons of Type 15 organic vs. composite felts and the potential amounts you can save by making composite.
From laboratory and commercial trial evaluations, a furnish con sisting of 36% fiber, 60% filler, and 4% latex gives optimum economics and physical properties. Our weight recommendation for a Type 15 composite felt is 35 lbs/480 ft. The strength of the composite felt would be equivalent to your 27 lb. organic felt.
The attached economics show that the raw material cost for the composite felt is higher than the all organic. However, the composite felt dries at least twice as fast and saturates at only 70% asphalt. This combination makes the total manufactured cost considerably less for the composite.
The manufacturing costs are divided into four parts. The paper and asphalt raw material costs are estimated to be 50% of the total manufactured cost. Energy associated with production of the unsaturated felt is estimated to be 25% of the total. Energy associated with saturation is estimated to be 10%. Wages, main tenance, administration, etc. are estimated to be 15% of the total. Regarding energy reduction associated with composite paper, another option would be to maintain current energy usage and increase pro duction .
Look over the attached economics and compare to your economic .evaluation. Upon completion! would be happy to discuss the matter in more detail with you. In the meantime, if I can be of any assistance please do not hesitate to contact me.
Sincerely,
Designed Products 2040 Dow Center 517/636-3280
Attachments
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AN OPERATING UNIT OF THE OOW CHEMICAL COMPANY
BIRD 013986
BIRD & SON, INC. ESTIMATED RAW MATERIAL COST
TYPE 15 FELT
RAW MATERIAL
Asphalt Corrugated Fiber Wood Flour . Calcium Carbonate Latex Flocculant
COST
$165 per ton $ 65 per ton $ 45 per ton $ 30 per ton $0.74 per ton $2.50 per ton
Corrugated Wood Flour Calcium Carbonate Latex Flocculant
Total RM Cost/Ton Total rm cost/Pound
ORGANIC
% $/Ton
75 $48.75 25 $11.25 -------- --
$60.00 3. OOt
COMPOSITE
$/Ton
36
--
60 4
2 Lbs/Ton
$ 23.40
--
$ 18.00 $ 59.20 $ 5.00
$105.60 5.28'
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PAPER MACHINE CONDITIONS
Basis Weight, lbs/480 ft^ Machine Speed, fpm Trim, Inches Pounds Stock/Min. Tons Stock/24 Hrs. Sq. Ft./24 Hrs.
Base Felt RM Cost/24 hrs. Base Felt RM Cost/Sq. Ft.
ORGANIC
27 ISO 144 101.25
72.9 2,592,000
$4,374.00 0.1694
COMPOSITE
35 150 144 131.25
94.5 2,592,000
$9,979.20 0.385*
SATURATION
Tons Asphalt/24 Hrs. Asphalt Cost/24 Hrs.
Saturated Felt RM Cost/24 Hrs. Saturated Felt RM Cost/Sq. Ft.
102.06 e 140%
$16,840.00
$21,214.00 0.8184
66.15 p 70% $10,915.00
$20,894.20 0.8064
MANUFACTURING COSTS'/SQ. FT.
Paper and Asphalt RM (50%) Energy Ass. Paper Production (25%) Energy Ass. Saturation (10%) Labor, Maintenance, Etc. (15%)
Total Manufactured Cost/Sg. Ft.
0.816 0.409 0.164 0.245
1.6364
0.806 0.204 (50% Of 0.409) 0.123 (75% of 0.164) 0.245
1.378*
SAVINGS
Savings per Sg. Ft. Savings per 24 Hrs. Savings per Year (350 Days) Tons of Asphalt Saved per Day
0.2584 6,687.36
$2,340,576.00 35.9
1 Percentages are of estimated total manufactured cost of an all organic felt.
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