Rotary forming apparatus

A rotary forming apparatus comprising:

• a separator configured to receive a gas flow having entrained fibrous material, the separator further configured to separate the fibrous material from the gas flow, the fibrous material forming mini-blankets, the mini-blankets having a longitudinal axis;
• and
• a milling apparatus positioned adjacent the separator and configured to receive mini-blankets exiting the separator, the milling apparatus further configured to grind the mini-blankets into fibers having a desired length, the milling apparatus including a plurality of cutters configured for rotation about an axis;
• wherein as the milling apparatus grinds the mini-blankets, the mini-blankets and the milling apparatus are arranged such that the longitudinal axis of the mini-blankets and the rotational axis of the plurality of cutters are substantially parallel.

A method for forming fibers having a desired length from a flow of gases and entrained fibrous material, the method comprising the steps of:

• intercepting the flow of gases and fibrous material with a separator;
• separating the fibrous material from the flow of gases, and depositing the fibrous material on an outer circumferential wall of the separator thereby forming mini-blankets, the mini-blankets having a length along a longitudinal axis;
• discharging the mini-blankets from the separator;
• intercepting the mini-blankets with rotating cutters in a milling apparatus, the milling apparatus positioned adjacent the separator;
• and
• grinding the mini-blankets with the rotating cutters into fibers having desired lengths;
• wherein the rotating cutters of the milling apparatus are configured to grind away a longitudinal portion of the mini-blankets.