PFM Screen's 2.5 layer forming fabric (also called support-shute double layer or double-layer extra design) is one of PFM Screen's best-selling forming fabric types. It adds extra weft yarns on the sheet side between the two regular cross-direction yarns of a standard double layer, increasing sheet-side fiber support density while reducing weft count on the machine side to enlarge three-dimensional drainage volume.
Description
PFM Screen's 2.5 Layer Forming Fabrics — also known as support-shute double layer fabrics or double-layer extra designs — represent an advanced evolution of the standard double layer structure. The "extra" designation refers to additional weft yarns inserted on the sheet side between the regular CD yarn positions. These extra yarns increase fiber support on the paper-forming surface (raising FSI) while the machine-side weft count is simultaneously reduced to create a larger three-dimensional drainage void. The net result is a fabric that simultaneously delivers lower wire mark, better fiber retention, and excellent drainage — PFM Screen's most versatile high-performance forming fabric type.
 16-Shed 2.5 Layer Structure Extra weft yarns on sheet side increase fiber support; reduced weft on machine side enlarges three-dimensional drainage volume |  Printing Paper Machine Application Most commonly used for printing, newsprint and specialty paper at 200–600 m/min on Fourdrinier and gap former machines |
01 Higher Sheet-Side FSI Extra weft yarns double the fiber crossing point support density on the paper-forming surface, minimizing wire mark on printing and specialty grades | 02 Larger Drainage Volume Reduced machine-side weft count enlarges three-dimensional internal void space, increasing drainage capacity without increasing hydraulic impact on the fiber mat | 03 CD Ridging Resistance Double MD yarn lock on the machine side withstands high machine-direction tension loads and resists cross-direction ridging — a major failure mode in fast-running machines | 04 Superior Abrasion Resistance Large-diameter machine-side weft yarns and long CD crimp length on the machine side provide extended abrasion life vs standard double layer fabrics |
| Property | Standard Double Layer | 2.5 Layer (This Fabric) |
|---|---|---|
| Sheet-Side Fiber Support (FSI) | Good | Better |
| Wire Mark Reduction | Good | Better |
| Drainage Volume | Good | Better |
| CD Ridging Resistance | Standard | Enhanced (double MD lock) |
| Abrasion Life | Good | Extended (large CD weft) |
| Standard Model Range | 4 models | 30+ models |
| Machine Type | OEM Examples | Speed Range | Key Application |
|---|---|---|---|
| Fourdrinier — Print / Writing | Voith, Valmet, Andritz | 200–600 m/min | Offset, coated, writing paper |
| Gap Former / Twin Wire | Valmet SymFormer, Voith DuoFormer | 300–600 m/min | LWC, newsprint, fine paper |
| Hybrid Former | Andritz, Valmet | 200–500 m/min | Print, specialty |
| Fourdrinier — Newsprint | Voith, Valmet, GL&V | 400–600 m/min | Standard newsprint |
| Fourdrinier — Board / Wrapping | Voith, Allimand, A.Celli | 200–500 m/min | Wrapping, board, onion-skin |
* OEM names for reference only. PFM Screen is an independent manufacturer not affiliated with the above OEMs.
Request a 2.5 Layer Forming Fabric Recommendation — 24-Hour Response Tell us your paper grade, machine type, running speed and fabric dimensions — PFM Screen will select the optimal 2.5 layer model from 30+ configurations and quote within one business day. WhatsApp: +86 153 6967 9157Email: polyestermesh@pfmscreen.com |
Feature
Superior Fiber Support Index (FSI) The extra weft yarns on the sheet side of the 2.5 layer structure maximize the Fiber Support Index — the number of individual fiber crossing points supported per unit area. Higher FSI directly correlates with lower wire mark, smoother paper surface, better formation uniformity and improved printability in the final paper product. | Excellent Sheet Release The smooth polyester monofilament sheet-side surface and precise FSI engineering produce clean sheet release at the couch roll — reducing web breaks, minimizing pick-up problems and improving reel quality. The 2.5 layer fabric excels in applications where paper surface quality directly drives product value: coated printing papers, high-quality offset papers and specialty grades. | 30+ Standard Models PFM Screen's 2.5 layer range encompasses over 30 standard configurations covering warp densities of 37–71 pcs/cm and air permeability of 5,000–8,000 m³/m²h. This breadth enables precise matching to specific paper grades, machine speeds and formation system geometries — without requiring full custom development for most applications. |
Double MD Yarn Lock A key structural feature of PFM Screen's 2.5 layer fabrics is the double MD (machine-direction) yarn lock on the machine side. This interlocking structure resists high MD tension loads and prevents the cross-machine direction ridging that can occur in standard double layer fabrics under high tension operation — extending service life and maintaining flatness throughout the run. | Large CD Crimp for Extended Life The large-diameter machine-side weft yarns with long CD (cross-machine direction) crimp length provide significantly better abrasion resistance than standard double layer fabrics on the same machine. This translates to longer service intervals and lower total fabric cost per tonne of paper produced — especially on high-speed gap former machines where mechanical wear is the primary fabric life limiter. | 16-Shed High-Performance Weave Many PFM Screen 2.5 layer models use a 16-shed weave pattern — the most complex configuration in the forming fabric range. The 16-shed structure produces the finest, most uniform sheet-side surface lattice of any non-triple-layer forming fabric, approaching triple layer surface quality at a lower price point. It is the first choice for high-quality printing papers and coated specialty grades at 200–600 m/min. |
Find the Right 2.5 Layer Model for Your Machine With 30+ standard models, PFM Screen's technical team will match the exact warp density, air permeability and weft configuration to your machine speed and paper grade. WhatsApp: +86 153 6967 9157Email: polyestermesh@pfmscreen.com |
Application
| Paper Grade | Basis Weight | Machine Speed | Representative Models |
|---|---|---|---|
| Printing Paper (offset, coated) | 60–130 g/m² | 200–600 m/min | 2B5608, 2B6208, 2B6216 series |
| Newsprint | 40–60 g/m² | 400–600 m/min | 2B5408, 2B5808 series |
| Wrapping Paper | 40–100 g/m² | 200–500 m/min | 2B3316, 2B5216 series |
| Board Grade (writing, coated board) | 150–300 g/m² | 200–400 m/min | 2B3316, 2B5008 series |
| Onion-Skin Paper | 15–30 g/m² | 200–500 m/min | 2B6208-1, 2B6408 series |
| Specialty / Technical Paper | 30–120 g/m² | 200–600 m/min | Contact PFM Screen for grade match |
| Stock Preparation | → | FORMING SECTION2.5 Layer Forming Fabric | → | Press Section | → | Dryer Section | → | Reel |
| OEM / Machine | Formation Type | Application | Recommended Model Series |
|---|---|---|---|
| Voith DuoFormer / Fourdrinier | Gap former / horizontal | Fine paper, newsprint | 2B5608, 2B6208 series |
| Valmet SymFormer / OptiFormer | Gap former | LWC, SC paper, fine paper | 2B6216, 2B6408 series |
| Andritz DeltaFormer | Hybrid former | Newsprint, printing paper | 2B5808, 2B6208 series |
| Voith / Valmet Fourdrinier | Horizontal Fourdrinier | Printing, wrapping, board | 2B3316, 2B5216 series |
| GL&V / Allimand Fourdrinier | Horizontal Fourdrinier | Print, writing, specialty | 2B5608, 2B5408 series |
* OEM names for reference only. PFM Screen is an independent manufacturer not affiliated with the above OEMs.
Match Your Machine to the Right 2.5 Layer Model Share your machine OEM, paper grade, formation type, running speed and fabric dimensions — PFM Screen will select from 30+ 2.5 layer models and provide a same-day recommendation. WhatsApp: +86 153 6967 9157Email: polyestermesh@pfmscreen.com |
Specifications
| Model | Warp Dia (mm) | Weft Top (mm) | Weft Bottom (mm) | Warp (pcs/cm) | Weft (pcs/cm) | Air Perm (m³/m²h) |
|---|---|---|---|---|---|---|
| 2B3316 | 0.28 | 0.20, 0.27 | 0.40, 0.40 | 37~38 | 40~41 | 6,000 |
| 2B3316-2 | 0.28 | 0.20, 0.27 | 0.45, 0.45 | 37~38 | 31~32 | 8,000 |
| 2B5008 | 0.17 | 0.13, 0.18 | 0.32, 0.32 | 55~56 | 48~49 | 6,500 |
| 2B5216 | 0.17 | 0.17, 0.22 | 0.27, 0.27 | 57.5~58.5 | 50~51 | 5,300 |
| 2B5408 | 0.17 | 0.13, 0.20 | 0.35, 0.35 | 59~60 | 43~44 | 6,300 |
| 2B5608 | 0.17 | 0.13, 0.18 | 0.22, 0.22 | 61~62 | 52~53 | 5,700 |
| 2B5608-4 | 0.17 | 0.13, 0.20 | 0.32, 0.32 | 61.5~62.5 | 55.5~56.5 | 6,900 |
| 2B5808 | 0.17 | 0.13, 0.18 | 0.22, 0.22 | 63~64 | 53~54 | 6,500 |
| 2B6208 | 0.17 | 0.13, 0.18 | 0.20, 0.20 | 68~69 | 56.5~57.5 | 5,500 |
| 2B6208-1 | 0.17 | 0.13, 0.18 | 0.20, 0.20 | 68~69 | 54.5~55.5 | 6,000 |
| 2B6216 | 0.17 | 0.13, 0.18 | 0.23, 0.23 | 68~69 | 61.5~62.5 | 5,600 |
| 2B6216-4 | 0.17 | 0.13, 0.20 | 0.35, 0.35 | 68~69 | 49.5~50.5 | 8,000 |
| 2B6408 | 0.17 | 0.12, 0.18 | 0.20, 0.20 | 70~71 | 57~58 | 6,200 |
| 2B6408-1 | 0.17 | 0.12, 0.18 | 0.20, 0.20 | 70~71 | 65~66 | 6,500 |
* This table shows a selection of 14 representative models from PFM Screen's full 30+ model range. Full specification list available on request. All values subject to manufacturing tolerances. Custom warp/weft configurations, widths and lengths available.
Q1: What is a 2.5 layer forming fabric and what makes it different from a standard double layer? A 2.5 layer forming fabric is a double-layer design enhanced with extra weft yarns inserted on the sheet side between the regular cross-direction (CD) yarn positions. The "2.5" designation reflects that the sheet-side effective weft density is approximately 1.5x that of a standard double layer, while the machine side retains the single-layer of weft for wear resistance. This extra sheet-side weft increases the Fiber Support Index (FSI) — the density of fiber crossing support points — while simultaneously reducing machine-side weft count to enlarge the three-dimensional drainage void. The result is better wire mark control, better retention and better drainage than a standard double layer, all in a single fabric — explaining why it is PFM Screen's best-selling forming fabric product line. |
Q2: Why is the 2.5 layer forming fabric called "support-shute" or "extra-weft" design? The term "support-shute" (also written "support-schute" or "support-CD yarn") refers to the extra weft (shute/CD) yarns added on the sheet side. These support-shute yarns are not regular full-width load-bearing CD yarns — they are additional fine-diameter yarns inserted specifically to increase the sheet-side fiber support contact density (FSI) without disrupting the fabric's fundamental double-layer drainage structure. The terms "double-layer extra design" and "extra-weft forming fabric" are used interchangeably with "2.5 layer" in different markets and by different OEM manufacturers — they all describe the same structural architecture: a double-layer fabric with added sheet-side weft yarns. |
Q3: Which paper grades and machine speeds is the 2.5 layer forming fabric best suited for? PFM Screen's 2.5 layer forming fabrics are optimized for paper machines running at 200–600 m/min producing printing paper (offset, gravure, coated), newsprint, wrapping paper, board grades, onion-skin paper and specialty papers. This speed range covers most modern Fourdrinier and gap former machines on printing-grade stock. For tissue or corrugated grades (which prioritize drainage over FSI), single layer or 1.5 layer fabrics are more appropriate. For the highest-speed, finest-quality printing and tissue grades above 600 m/min, triple layer forming fabrics are recommended. The 2.5 layer covers the critical middle ground where high FSI, good drainage and reasonable machine-side life are all simultaneously required. |
Q4: How does the extra sheet-side weft improve paper quality in a 2.5 layer forming fabric? Paper quality is directly influenced by how the fiber mat is supported during the initial dewatering phase in the forming section. More fiber crossing points supported per unit area (higher FSI) means the sheet is dewatered more uniformly, individual fibers are less likely to collapse into mesh gaps, and the wire mark pattern is shallower and finer. In practical terms, upgrading from a standard double layer to a 2.5 layer forming fabric on a printing paper machine can improve paper surface smoothness (Bekk or Bendtsen smoothness), reduce two-sidedness, improve formation index and reduce coating weight requirements for surface sizing or pigment coating — all of which drive improvement in printability and final product value. |
Q5: Can PFM Screen's 2.5 layer forming fabrics replace Voith, Valmet or Andritz OEM forming fabrics? Yes. PFM Screen is an independent forming fabric manufacturer serving paper mills worldwide as a direct replacement for OEM-branded forming fabrics from Voith, Valmet (Metso), Andritz and other suppliers. PFM Screen's 2.5 layer fabrics are manufactured on the same European TEXO and Jurgens weaving equipment used for premium forming fabrics, and are endlessly seamed on Austrian WIS automatic seaming machines. To specify a replacement, provide PFM Screen with your current fabric model number, machine OEM, paper grade, machine speed, fabric width and perimeter. PFM Screen will identify the matching or equivalent model from the 30+ 2.5 layer configurations and confirm lead time within 24 hours. |
Q6: What is the difference between 8-shed and 16-shed 2.5 layer forming fabrics? The "shed" count refers to the number of heddle positions in the weaving cycle and determines the weave pattern complexity. In the 2.5 layer range, model numbers ending in "08" use an 8-shed weave, while those ending in "16" use a 16-shed weave. The 16-shed configuration produces a finer, more complex surface lattice with a higher FSI for the same warp density — making it the preferred choice for the highest quality printing grades where surface smoothness is paramount. The 8-shed variant offers slightly better drainage (higher air permeability at equivalent warp density) and is preferred for grades where drainage rate is more critical than extreme surface quality — such as newsprint and standard writing paper. The model series 2B5608 (8-shed) vs 2B5216 (16-shed) illustrates this trade-off: both use similar warp densities but different air permeabilities and FSI levels. |
Q7: How many 2.5 layer forming fabric models does PFM Screen offer and how do I choose? PFM Screen offers over 30 standard 2.5 layer models in production, covering warp densities from 37 to 71 pcs/cm and air permeabilities from 5,000 to 8,000 m³/m²h. Model selection is driven by: (1) Machine speed — faster machines require higher warp density fabrics; (2) Paper grade — finer quality grades need higher FSI (16-shed, fine top weft diameter); (3) Formation system — gap formers need fabrics with higher MD strength and CD stability; (4) Furnish type — recycled fiber furnishes with high ash/filler content benefit from higher drainage models. PFM Screen's technical team will review your specific requirements and recommend the optimal model. Contact us with your machine details and current forming fabric specification for a same-day recommendation. |
Q8: What is the lead time and minimum order quantity for a 2.5 layer forming fabric? PFM Screen accepts single-fabric orders with no minimum order quantity. Standard lead time for a 2.5 layer forming fabric from order confirmation to shipment is typically 3–5 weeks, depending on fabric dimensions and whether the specification requires a non-stocked monofilament diameter. For standard models in the 2B5608 and 2B6208 families, production can sometimes be expedited to 2–3 weeks. Mills ordering replacement fabrics regularly can discuss a scheduled supply arrangement with PFM Screen to reduce lead times further. Contact us via WhatsApp (+86 153 6967 9157) or email (polyestermesh@pfmscreen.com) with your specification for a formal quotation and lead time within 24 hours. |
Get Your Custom 2.5 Layer Forming Fabric Quote — 24-Hour Response Send us your paper grade, machine type, speed, fabric width and perimeter — PFM Screen will select from 30+ models and respond with specification and pricing within one business day. WhatsApp: +86 153 6967 9157Email: polyestermesh@pfmscreen.com |
