INTERNATIONAL MAGAZINE AND WEBSITE ON TISSUE PAPER MACHINERY AND TECHNOLOGY
This issue is distributed to Tissue Paper Mills and Tissue Converters in Europe, Middle East, Africa + bonus countries.
Profitable Solutions For Paper Industry
like no other
THE NEW GENERATION OF SEAMLESS STEEL YANKEE DRYER SHELLS
Meet us at MIAC 2019, Lucca - Italy, October 9-11, booth nÂ° 1
Pictures are shown for illustrative purposes only; actual products may vary due to A.Celliâ&#x20AC;&#x2122;s R&D activities.
no longitudinal welds no welds at head to shell joint minimum root shell thickness for maximum drying capacity shell stress controlled by rib geometry and head to shell corner design innovative shape of internal grooves stronger Yankee shell working flexibility at different pressures
seamless steel is the future A new manufacturing technology allows the entire shell to be forged from a single piece of steel with no welds, for all diameters needed. The elimination of welds sensibly reduces mechanical issues while at the same time guaranteeing greater solidity and improved heat transmission.
INTERNATIONAL MAGAZINE AND WEBSITE ON TISSUE PAPER MACHINERY AND TECHNOLOGY
MAY 2020 EDITOR-IN-CHIEF Gianmaria Pfeiffer email: firstname.lastname@example.org EDITORIAL DIRECTOR Mariella Nasi STAFF EDITOR Fabrizio Vallari ADVERTISING Laura Lupi email: email@example.com EDITORIAL ASSISTANT Letizia Besana LAYOUT & DESIGN Francesca Acqualagna WEBSITE Francesco Tosi PRINTER Logo Srl - Padova
6 Western European tissue consumption 2018 14 Fabio Perini introduces Pivot Solutions, the new center of excellence for the Tissue industry 18 Tissue manufacturer Fripa relies on integrated solutions from Voith
22 Tedim, tissue and cleansing: story of an excellence from South Italy 26 All strength is not created equal
Edipap S.r.l. Via Pordenone 13 20132 Milano - Italy phone: +39 02 21711614 email: firstname.lastname@example.org website: www.edipap.com TissueMAG - registration number 133 11/04/2017 - Court of Milan - Italy. Copyright 2020 by Edipap S.r.l. with all rights reserved. No part of this magazine may be reproduced or copied by any means whatsoever without written permission of the editor. TissueMAG is published by EDIPAP S.r.l. Statements of fact and opinions expressed are those of individual authors or companies; Edipap S.r.l. assumes no responsibility for such statements and opinions. The articles are received by TissueMAG directly from the companies which are responsible of all the text and content (also if in the magazine the article is signed by TissueMAG).
Circulation 3,652 copies
30 The art of maximizing production 34 Up to the finished roll: Futura moves boundaries again in tissue converting 38 Toscotec fired up its 200th TT SYD 42 Moviroll the solution for safe material handling 46 A.Celli Paper: together towards tomorrow 50 Gambini America: ready to get in the game 54 Digital enablers at Sulzer. Smart and connected equipment 58 Officine Airaghi: maximum durability and reliability. Customized quality design 62 Key equipment: the case for conventional thinking 66 MARE as a partner to approach Halogenated Organic Compounds Management in tissue making 70 Overcoming frontiers: optimized tissue pressure roll position with SchĂ¤ferRolls tisQ.R cover 74 Ecova Paper Wrap from Little Rapids Corporation on the Infinity Eclipse T4 Multi-pack Wrapper 78 Tecno Paper Innovative Tissue Winding Technology 82 Solar Turbines: a new concept of service 86 Amotek, from Ecological agility to Innovation ability 90 OCME and Robopac: advanced solutions for monitoring tissue plants 94 Effectively solving tissue production, converting and packaging problems using event capturing camera systems
MAY 2020 CIRCULATION This issue of TissueMAG is distributed in 3,652 copies to Tissue Paper Mills and Tissue Converters in: Albania, Algeria, Angola, Austria, Bahrain, Belarus, Belgium, Bosnia-Herzegovina, Bulgaria, Cameroon, Croatia, Cyprus, Czech Republic, Egypt, Estonia, Finland, France, Germany, Ghana, Great Britain, Greece, Hungary, Iceland, Iran, Ireland, Israel, Italy, Ivory Coast, Jordan, Kenya, Kosovo, Kuwait, Latvia, Lebanon, Lithuania, Macedonia, Malta, Moldova, Morocco, Nigeria, Norway, Palestine, Poland, Portugal, Reunion, Romania, Saudi Arabia, Serbia, Slovakia, Slovenia, South Africa, Spain, Sweden, Switzerland, The Netherlands, Tunisia, Turkey, United Arab Emirates.
NEXT ISSUE: NOVEMBER 2020
98 SENNING first-class machines for first-class products 102 O.M.C. Collareda and the environment: water, a precious asset to be treated with care 106 New Microline Fast Wrap: increasingly higher performance gives Tissue sector a boost 110 Complete and specific plants for the paper industry 114 Enfasi-SINERGYâ&#x20AC;Ś PM machine rebuilding 118 SABA AUTOMATION presents its new end-of-line solutions for the tissue and paper market 122 Paprima Industries pushes the boundaries of high-pressure fabric cleaning 126 Towards energy-efficient and economical Tissue production with RunEco solution 130 The machines speak: letâ&#x20AC;&#x2122;s listen to them 134 Packaging in line with your products 138 Global strength, local presence 142 VAKUO GmbH vacuum pumps and systems, formerly CUTES Europe Ltd. has specialized in optimizing existing vacuum systems in the paper industry 146 BINVISION DEVICE 150 Second Hand Machines A Matter of Trust 154 Paniker: where know-how and engineering united for the best adhesive solutions 158 Generating trust with clean, efficient power generation 162 Bonetti: High and Low Pressure Shower Solutions 166 Fomat, systems and technology for paper mills 170 Pure performance is about constant development 174 AZMEC is always looking for the discovering of a better and improved product 178 Bolzoni Auramo partner in AGV applications 182 Two specialists, no compromise! 186 Tissue news around the world
Western European tissue consumption 2018 Disappointing year with slow growth. by: Esko Uutela, Principal - Fastmarkets RISI
estern European tissue consumption has grown in recent years at substantially lower growth rates than in the past, with 2015 the only exception. Tissue consumption grew by 1.2% in 2013, 0.8% in 2014 and an encouraging 2.7% in 2015, but then returned to a lower level of 0.8% in 2016, but recovered to 1.2% growth in 2017. Our current figures for 2018 suggest that the Western European market expanded by only 0.7%, even less than in the weak years 2014 and 2016. Some smaller revisions in the foreign trade figures are still possible, but even these will not change the fact that market growth was weak in 2018. In 2013-2018, tissue consumption
Table 1 Recent Western European tissue consumption by country Consumption in thousand tonnes
Tissue consumption Country
Central Europe & British Isles
ÂŠ 2020 Fastmarkets RISI. All Rights Reserved.
grew by 402,000 tonnes in Western Europe, about 80,000 tonnes per year on average. Having a slightly longer perspective, the average five-year growth rate (2013-2018) was not more than 1.2% per year, so last yearâ&#x20AC;&#x2122;s development was below trend line growth. The current outlook is that like the economy, Western European tissue consumption has lost momentum. There are no indications that this slowing growth trend will stop in the near future, and we have adjusted our forecast downward accordingly. The driving forces for tissue consumption are weak, as population growth remains low in Western Europe, and
the high average share of retailer labels in the consumer tissue business keeps the consumption structure static as retailers dictate the specifications for their products and there is little room for innovations and new product launches, which are an important driver in the better-performing US tissue market. Also, one of the important factors in the past was the shift to more plies in toilet tissue and kitchen towels, but this development has now slowed as there is no need to continue on this path, with four - and even five - ply toilet paper being offered in a number of Central European countries, such as Germany.
70 60 50 40 30 20 10 0
© 2020 Fastmarkets RISI. All Rights Reserved.
▲▲Figure 1. Average share of retailer labels in Western European consumer tissue, 2010-2018. Relative share, percent.
▼▼Figure 2. Average retailer label volume shares in Western Europe by country, 2018. Thousand tonnes.
One of the main features of the Western European consumer tissue market is the high share of private or retailer labels. Nowhere else in the world have retailer labels gained such high popularity as in Europe. This development began in the 1990s and had its strongest growth phase 10-15 years ago, but there seems to be no absolute limit for the growth. However, it is hard to believe that in any country there would be only retailer labels available, so the 100% private label share may never be reached. In Western Europe on average (the averages are weighted by the consumption volume by country) the current volume share of retailer labels is now around 66% and the value share slightly lower, at close to 62%. Since 2010, the volume share has grown by a relative average of 0.5% per year, or by an absolute 0.3 percentage point per year. One should note that the gap between volume share and value share has declined from 6.2 percentage points in 2010 to 4.5 percentage points in 2018. This means that prices of retailer labels are now closer to prices of company brands. There continue to be major differences between countries due to the structure of retailing, power of local suppliers and consumer attitudes. Germany leads the list with a very high 85.0% share of retailer labels, followed by Spain (81.4%) and Greece (81.4%). Finland and Italy have the lowest retailer label shares, at 29.8% and 35.3%, respectively. In Finland, the tissue business is firmly in the hands of two main suppliers, Metsä Tissue and Essity, both of which want to offer their own brands rather than retailer labels. Retailing is also very much dominated by two main groups, Kesko (K Group) and S Group (cooperative known also as Sokos). Recently, Lidl has gained reasonable market share in Finland and this has led to some increase in the retailer label share. In Italy, the fact that retailing is more fragmented than in many other countries, especially in the south of the country, and the local tissue industry is strong are the main reasons for the rather low retailer label share. Among other countries, the Netherlands also has a retailer label share less than 50%; all other Western European countries are above that. Unfortunately, there are no figures for Denmark available for 2017-2018, but its average volume share in 2016 was around 62%.
Retailer labels continue to gain share but rather slowly
© 2020 Fastmarkets RISI. All Rights Reserved.
800 700 600
Germany, the largest market, contracted in 2018
-400 ÂŠ 2020 Fastmarkets RISI. All Rights Reserved.
â&#x2013;˛â&#x2013;˛Figure 3. Tissue trade balance in Western Europe by country, 2018. + Net exports - net imports, thousand tonnes.
and new capacity was built in the country and imports collapsed. In 2014, Western Europe showed a zero trade balance, but net imports started to grow: 50,000 tonnes in 2015, 97,000 tonnes in 2016, 135,000 tonnes in 2017 and 137,000 tonnes in 2018. By country, Italy continues to be the main net exporter; Sweden, Finland and Portugal are also net exporters. All other countries were net importers in 2018. The UK is by far the largest net importer with net imports of almost 400,000 tonnes in 2018. Turkey is a major source of parent rolls for independent tissue converters, but the country imports from many countries, both in Europe and overseas.
Western European net trade in tissue parent rolls and converted products has been negative in recent years, which means imports have been higher than exports. In 2012-2013, Western Europe was a net exporter, mainly due to the fact that Russia was a major importer, but then its currency weakened substantially
The sub-region of Central Europe and the British Isles showed average growth of 0.8% in 2018, negatively affected by the fact that statistically the German market volume declined by 0.8%, based on apparent tissue consumption. The UK, the second-largest market, had growth of 1.2%, which largely counterbalanced the German volume decline. This means that the two largest markets, accounting for 38% of regional consumption, did not contribute to growth at all, which
Table 2 Western European tissue production, imports, exports and consumption, 2018 Thousand tonnes
Growth (%/a) 2018/2017
Central Europe & British Isles
© 2020 Fastmarkets RISI. All Rights Reserved.
substantially lowered the Western European average. The Benelux countries recorded the most positive development in the sub-region, with tissue consumption growing by 5.7% in Belgium and 2.5% in the Netherlands. Austria and Ireland showed modest growth of 1.2% each, while consumption in Switzerland remained at the same level as in 2017.
Southern European countries showed varying developments On average, Southern European tissue consumption grew by 0.7% in 2018, which corresponds to the average Western European growth rate. But individual countries behaved quite differently. Malta and Spain recorded the
highest relative growth rates of 7.6% and 4.2%, respectively; however, Malta recorded small volume growth of about 500 tonnes. Spain finally reached and exceeded the pre-recession consumption level of 2007 and 2008. This shows how badly the Spanish tissue market suffered from the economic downturn and its consequences of high unemployment and reduced purchasing power of consumers - it took ten years to recover! Italy is now the largest tissue market in Southern Europe, having taken this position from France in 2017. Italy’s apparent tissue consumption grew very strongly, by 7.5% in 2017, but stagnated and declined by 0.2% in 2018. The five-year average growth rate for 2013-2018 shows trend line
(for example, fewer plies than in Germany) and low penetration degree in some segments, particularly in napkins and facial tissue/hankies, are major reasons. Greece has been in economic turmoil in recent years, and the wave of closures a few years ago has led major growth in imports. Independent converters have strengthened their position in the country, and parent roll imports from Turkey, Italy, Romania and Indonesia have seen a substantial increase. Greek tissue consumption showed growth of 2.5% in 2018, according to our data. After a strong increase of 4.1% in 2017, Portuguese tissue consumption took a break in 2018 and remained at the same level as in 2017. New domestic capacity that started up in 2015-2018 has made the country a major exporter and strengthened its domestic supply as well.
Maturing growth in the Nordic countries
growth of 2.1%, illustrating that there is still growth potential, especially in the AfH sector and southern Italy. French tissue consumption has stalled at its low level. The country’s per capita consumption of 13 kg per head is the lowest in Western Europe. In the past three years, tissue consumption has contracted year after year. We do not fully understand the reasons for this as the country is otherwise well developed, but suppose the relatively high share of retailer labels, traditionally simpler product structures
Tissue consumption contracted by 0.4% in the Nordic markets in 2018, due to the declines in Sweden (-2.0%) and Norway (-1.0%). In conclusion, the Nordic markets are relatively mature because of their high per capita consumption, advanced AfH tissue use and moderate population growth, only helped by immigration. Finland and Denmark booked some moderate growth in 2018, of 2.2% and 1.0%, respectively. In terms of volume, these changes are unimportant. The smallest Nordic market, Iceland, showed a small decline of 1.6% but in terms of volume this was less than 100 tonnes. ●
FASTMARKETS RISI 4 Alfred Circle MA 01730 Bedford - USA ■ website: www.fastmarkets.com ■ phone: +1 866 271 8525 ■ email: email@example.com
▲▲Constellation™ - Detail of the 4 rolls rewinding technology.
he Tissue market is in continuous evolution. The volatility of the cost of pulp and a highly competitive market open new challenges for Tissue manufacturers and converters, who need to anticipate the competitors by offering distinctive products, with short time-to-market while maintaining profitability. In order to support Tissue Manufacturers in this challenge, Fabio Perini has decided to launch Pivot Solutions, the new center of excellence for the Tissue industry, combining all the know-how of the Business Area Körber Tissue
companies. The aim is to support customers in developing new products, both roll and fold, with a turn-key solution that allows drastically reducing time-to market and investment risk. Pivot Solutions combines the expertise of Fabio Perini and MTC in the converting sector, the in-depth knowledge of embossing solutions of Engraving Solutions and Roll-Tec, the latest acquisition of the Körber Group, and the ability of analyzing machine and product quality data of the Pivot laboratories. “Today Fabio Perini can support companies in the development of new products or in the upgrading of existing ones without
Fabio Perini introduces Pivot Solutions, the new center of excellence for the Tissue industry All the expertise of the Business Area Körber Tissue now available for Tissue manufacturers. by: Fabio Perini SpA
requiring to stop the production lines”, comments Dario Giannini, Customer Product Innovation Manager. “With Pivot Solutions, our customers will be able to test new prototypes or to optimize the characteristics of their current products by producing small lots, recreating, where necessary, the conditions of production. Thanks to the data analysis carried out by the pilot line, the Fabio Perini experts, will be in condition to help customers find the best solution to their needs, by identifying the best combination of tissue paper, technology and finished product characteristics.”
Pivot Solutions is “Glocal”, as it is locally present all over Fabio Perini plants worldwide and has a global knowledge of the Tissue market thanks to its people’s experience and the interaction between the plants. Today, Pivot Solutions has five pilot lines, among which the new Constellation S6 Pilot Line and three Pivot Labs, located across GreenBay, Lucca, São Paulo, Joinville. “The first Pivot Lab was inaugurated in Lucca in 2016. Today with the local presence at our worldwide facilities, the Pivot Labs experts work every day in contact with customers to help them take informed decisions”, states Dario Giannini.
▲▲Pivot Solutions Our Services.
■■ Pivot Lab - Lucca Headquarters.
Pivot Solutions: unlock the full potential of your business like never before “The uniqueness of Pivot Labs lies in discovering the correlations between the quality of the finished product and the setting of the line parameters in order to obtain the best product recipe, with higher efficiency while lowering costs.” In the new center that was inaugurated in Lucca in April 2020 the first Pilot Line, with the breakthrough Constellation™ S6 4-rolls technology was installed, able to achieve a production speed up to 700m/min. This new pilot line is equipped with our most advanced technology such as Warm Up, the new embossing system with engraved steel rolls, launched last November thanks to the cooperation with Roll-Tec, SAM Caliper, the smart control system capable of measuring paper caliper before and after the embosser while the line is running at full speed, Leonardo, a lotioner station capable of finely controlling the quantity of lotion applied by means of a special anilox roll in contact with paper web, and Aquabond, the glue-free lamination system that allows use of water instead of glue to achieve ply bonding through lamination. ●
■■ Pivot Lab - Paper measurements.
FABIO PERINI SPA Via Giovanni Diodati 50 55100 Lucca - Italy ■ website: www.fabioperini.com ■ phone: +39 0583 4601 ■ email: firstname.lastname@example.org
“SCA Pure, certified pulp with a fantastic environmental profile.“ Jessica Sjöberg. Product Manager, SCA Pure.
Pure sustainability Today, consumers demand increasingly better pulp products, with reduced impact on the environment. With our strong environmental profile and a low carbon footprint, we can help our customers to reach their environmental goals. We have named our product SCA Pure. Pure, as in pure performance, pure profitability, and pure sustainability. Outstanding properties SCA Pure is our premium quality NBSK pulp, offering outstanding properties. This vitally includes a highly robust tensile strength. It’s complying with both FSC® (FSC C013162) and PEFC™ (PEFC/05-33-132). Also available as both TCF and ECF, in a broad range to meet specific customer demands.
Our state-of-the-art mill We produce pulp in an extremely energy-efficient process. The entire process is a bio-loop, making optimal use of all the resources available. This reduces the carbon footprint of both the mill and the surrounding society by 50 percent. Welcome We are always keen to learn more about our customers needs. Visit our mill and well-managed forests in northern Sweden. For more information, visit SCA.com and get in touch with your local sales representative.
Tissue manufacturer Fripa relies on integrated solutions from Voith In the growing international tissue paper market, paper manufacturers focus on the reliability of equipment by: Voith GmbH & Co. KGaA and its technical innovations. Growing market - growing demands With demand constantly rising, not only must energy-efficient and resource-saving production be ensured, but increasing customer demands also require the highest quality standards. This is also the case with the tissue manufacturer Fripa in Miltenberg.
Interplay of quality and technology still convinces today Highest product quality for papers and their packaging has always been the top priority for
Our tailor-made measuring and diagnostic services have been specially developed for the requirements of paper production 18
the German tissue manufacturer. Voith’s overall concept of innovative technology and optimal operating costs was one of the decisive factors that led Fripa to award the contract for delivery of the new TM 7 in July 2013. A key point was the optimal complementation of quality and technology and the mutual understanding of these values in a sustainable partnership. Today, we can look back on many years of trusting and successful cooperation. “Our success is the result of hard work and a long-standing cooperation based on partnership”, explains Verena Queck-Glimm, Executive Partner at Fripa. “With the innovative and energy-efficient technology of the TM 7, we ensure the best quality standard of our products in a highly competitive environment.”
Innovative technologies combined The TM 7 bundles decades of manufacturing experience of the Heidenheim-based paper machine manufacturer across the entire tissue
About the Voith Group
he Voith Group is a global technology company. With its broad portfolio of systems, products, services and digital applications, Voith sets standards in the markets of energy, oil & gas, paper, raw materials and transport & automotive. Founded in 1867, the company today has more than 19,000 employees, sales of € 4.3 billion and locations in over 60 countries worldwide and is thus one of the larger family-owned companies in Europe. The Group Division Voith Paper is part of the Voith Group. As the full-line supplier to the paper industry, it provides the largest range of technologies, services, components and products on the market and offers paper manufacturers solutions from one single source. The company’s continuous stream of innovations takes papermaking to the next level and facilitates resource-conserving production. With its Servolution concept, Voith offers its customers tailored service solutions for all sections of the production process. Voith Papermaking 4.0 ensures that equipment is optimally connected, while the secure use of generated data enables paper manufacturers to improve plant availability and efficiency.
▲▲The TM 7 is one of the most efficient and fastest machines in the world, reliably ensuring the high quality of Fripa products.
world, reliably ensuring the high quality of Fripa products. Today, the TM 7, with working width of 2,700 mm, produces a sophisticated range of hygiene papers - from absorbent cleaning and kitchen towels to soft toilet papers based on 100% chlorine-free pulp.
The guarantees for success
▲▲Visiting Fripa (from left to right): Verena Queck-Glimm, Executive Partner, Fripa Papierfabrik Albert Friedrich KG; Jan Wohlbold, Managing Director, Fripa Papierfabrik Albert Friedrich KG; Martin Jauch, Senior Vice President Tissue, Voith Paper and Marcus Schwier, Vice President Sales Tissue EMEA, Voith Paper.
production process. Voith supplied the complete production line - stock preparation, approach flow system, tissue machine including auxiliaries, electrification, automation and engineering of the entire plant. The scope was rounded off with all installation and commissioning services, as well as a clothing package covering several years. The result of the complete package was a highly efficient tissue machine that produced the first toilet paper in November 2014 after 16 months of project duration and achieved a maximum speed of 2,100 m/min only a few months after startup. The TM 7 is thus one of the most efficient and fastest machines in the
he roots of Fripa Papierfabrik reach back to 1911, when Hermann Friedrich founded a “paper processing company” in Berlin, Germany. Already taken over by his sons Albert and Kurt in 1932, the new Fripa paper factory (short for Friedrich Papier) was finally established in Miltenberg in 1948 under the management of Albert Friedrich. Fripa stands for high-quality hygiene papers that meet the constantly growing demands for hygiene in modern society. Today the company is a sought-after partner in the international hygiene paper market and is known for its particular flexibility and reliability. Thanks to its extensive experience, Fripa offers the trade products that are mature in every respect. This is complemented by a grown understanding of markets and people - and the passion to constantly rethink tissue paper.
The NipcoFlex T shoe press and Yankee cylinder EvoDry Y enable high speeds with reduced energy consumption. Even after the press section, an increased dry content is achieved, which reduces the need for thermal energy by up to 20%. Innovative solutions also offer advantages in the area of spray mist minimization. “With the Voith LowMist Former, we succeed in producing high-quality tissue products in a dry and clean environment”, says Christoph Maaß, Production Manager of the TM 7. “Compared with active vapor extraction systems, the LowMist Former is a very smart solution. Without using any additional energy, the steam is removed from the crescent former. The TM 7 operators appreciate the user friendliness and dry ambient conditions.”
Partnership with a promising future “Fripa is a very important partner in the field of tissue. We are available to the industry as a solution provider to jointly implement innovative and sustainable concepts that give our customers the decisive competitive advantage”, says Martin Jauch, Senior Vice President Tissue at Voith. The signs point to partnership in the future as well. The new Managing Director, Jan Wohlbold, assumed responsibility at the Miltenberg location in October 2019. “We look forward to shaping the future together and to having Voith at our side as the competent partner in the paper industry”, confirms Jan Wohlbold. “The digital solutions can also reveal interesting potential for our tissue production process.” ●
VOITH GMBH & CO. KGAA St. Pöltener Straße 43 89522 Heidenheim - Germany ■ contact person: Christina Garre, Manager Market Communication EMEA ■ phone: +49 7321 37 6157 ■ email: email@example.com
us at t e e M TALY I / C MIA
Your mission, Our challenge
With innovative solutions and specialised chemical applications, we support you in developing successful and sustainable products that will improve and sharpen your competitiveness. Do you want to know more? Please visit our stand 165 at Miac Lucca/Italy, October 14 - 16 BIM Kemi
â&#x20AC;˘ firstname.lastname@example.org â&#x20AC;˘ www.bimkemi.com
Born in 2006 as a producer of single-ply napkins and toilet paper, in a few years Tedim succeded in the market, first in Campania and then in the whole South of Italy, supplanting national brands thanks to the excellent value for money of their products. The exponential growth of the business and the product range allowed the company to enter the detergency, home care and personal care sector in 2016. Tedim, who last year invested in three OMET TV 840 lines, has grown with an ambitious vision and an effective and forward-looking management: their story is told in this interview by Nunzio Moccia, Product Marketing Manager by: TissueMAG of the company. 22
â&#x2013; â&#x2013; OMET TV 840 allows high performance and low maintenance for a very effective production.
TV 840Tronic: top level of automation and efficiency
Tedim, tissue and cleansing:
story of an excellence from South Italy
r. Moccia, tell us about Tedim’s grow path and its most important results. Tedim was born in 2006 with the paper production and converting. At the beginning we had few machines, and we produced only single-ply napkins and toilet paper under the Corona brand. Gradually we expanded the range by introducing new brands: Inpiù, Expert, Volè for the paper unit; Dinamo, Lusso, Biancofà, Elle for the cleansing sector we entered in 2016. What did allow such a rapid growth in rather difficult years for the general economy? Good products and private labels. In 2006-2007 the market was dominated by a few national brands. We launched our own brand in Campania, and we were the first. People liked it because we offered high quality and affordable prices compared to the national brands: our exponential growth was starting. This allowed big profit margins and we could increase production and create new brands. From a commercial point of view, what’s your positioning on the market? We only sell in Italy and in particular in the South: Campania, Sicily, Puglia, Basilicata and Lazio. We have not reached other regions or countries yet: these are our next objectives. How is your production organized today? What are your main product lines? In recent years, the strong increase in production led us to purchase new machines and we had to move to a new plant of 20 thousand square meters in 2016. Now we are
ttOne of OMET TV 840 in production at Tedim Industry facilities.
What growing prospects do you see for your company?
▲▲Perfect quality napkins delivered by OMET TV 840 at Tedim Industry.
working with three OMET lines for single ply napkins (purchased last year), an OMET line for two-ply napkins, one industrial line and two lines of toilet paper/kitchen towels, one for rolls and another machine to make a particular napkin of half a meter size, with different packaging. What reasons did lead you to invest in several OMET lines? We purchased 4 OMET lines in the last 3 years to satisfy our increase in production. Our older machines had limited performance. OMET lines have an excellent daily productivity, at high speed. What do you appreciate most about OMET brand? Certainly the productivity, and the strong structure of the machines. Thanks to their features, we have been able to satisfy the growing market demand. With the two-ply napkins line we had to contact OMET service and they have always been effective and available, promptly solving any kind of problem. This is very important for a converter: we often talk about the product, but sometimes it is thanks to the service if we decide to continue a collaboration.
OMET SRL Via Caduti Lecchesi a Fossoli 22 23900 Lecco - Italy ■ website: www.tissue.omet.com ■ phone: +39 0341 282661 ■ email: Ometemail@example.com
We certainly expect an increase of our presence on a national level. The goal is to develop our brands, by avoiding outsourcing and investing in communication and marketing to establish our most important brand, Corona, in other regions. In Campania and in the southern regions the market is quite saturated so we are expanding in other areas, first with the sales network and then with the production. How do you face market changes and innovation? We rely heavily on innovation. Corona has undergone a restyling of brand, packaging and quality of the product. Today some of our products have a more delicate texture, they are more resistant and softer, and we have also focused on aesthetics to improve the visual impact. It is always a private label product, but we have invested heavily in quality. How do you see the tissue sector at the moment and in the future? I think that paper market hasn’t any risk of crisis and instead is registering a growth that offers important opportunities to operators. The work is continuous and the market is solid, there are no swings that can prelude a crisis. But I see development opportunities outside our traditional territory. ●
ttOMET TV 840 is the ideal solution for high performance converting.
Two Specialists No Compromise
Kawasaki Gas Turbine Europe GmbH Nehringstraße 15 · 61352 Bad Homburg, Germany Phone: +49 (0) 6172 / 7363-0 · Fax: +49 (0) 6172 / 7363-55 E-Mail: firstname.lastname@example.org · www.kawasaki-gasturbine.de
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is not created equal Strength is no longer a value-added component of creped products; it is a requirement for most if not all consumer brands. There are many methods employed in the industry to achieve a stronger product. by: Daniel Glover, Innovation Director - Pulp & Paper, Buckman
t is essentially impossible to have a strong final product on the shelf or in the dispenser without a properly strong base sheet. Stated another way, a strong tissue product begins with a strong base sheet. The process to achieve the required strength makes all the difference in the final productâ&#x20AC;&#x2122;s appeal. All strength is not created equal. A discussion follows of the most common way to achieve strength, as well as a new way. Refining: Most if not all tissue manufacturers utilize refining to get additional strength development. Fibrillation of the fibers creates bonding sites essential for strength development. The old adage that if a little is good, more must be better certainly does not apply to refining in tissue mills. Refining creates fines and flattens fibers. Flattened fibers are stiffer and less bulky. Loss of bulk is certainly not desirable. As drape and bulk are often used as measures of softness, these base sheet properties are going in the wrong direction for a soft sheet. Equally as detrimental are the fines that are created by refining. These fines reduce drainage, reduce softness, impact hand feel, create dust and become part
of the coating on the Yankee. The objective is three-dimensional structure of the fiber or creating excessive amounts of fines. A new approach: what if there was a way to obtain the ideal amount of fibrillation without flattening or cutting the fibers? There may be
â&#x2013;źâ&#x2013;źRefined & Untreated (SEM 500X).
▼▼Refined & Treated with Maximyze® (SEM 500X).
a way to approach perfection. Enzymes are the answer. Certain cellulase enzymes are effective at preconditioning the fiber ahead of refining. This enzyme assisted refining in tissue is known but not well adopted in the industry yet. How does it work? A cellulase is an enzyme
found in nature that helps assist the microbial processing of cellulose. There are many classes of cellulases in nature. The ones that are useful for tissue makers are those that only react with the surface of the fibers. These specific enzymes break the bonds necessary to create fibrils that remain attached to the fiber. Breaking these bonds allows for refining to be more effective at lower energy input. This lowered energy input reduces cutting and flattening of the fibers while maintaining the desired bonding strength. Why isn’t it ubiquitous? There are many reasons or objections that tissue manufacturers will point to in order to resist the enzyme alternative. These objections have been mitigated over the last few years. In order to address these issues, it is necessary to cover the history of cellulases in tissue. 1st generation products: the first products used non-specific, unrefined, crude enzymes. These enzymes were not always stable, contained side activities and were expensive to produce. The manufacturing and purification techniques were not very effective. Advances in manufacturing, including separation techniques, led to the next generation.
■■ With the addition of Maximyze® 2596, tensile target was maintained while softwood was reduced.
2nd generation products: these products are cleaner, purer and have minimal side activities. These enzyme products use stabilization additives to keep the activity level even under tissue mill conditions. These products were generally a single, pure enzyme stabilized with other additives. This generation gained market acceptance. 3rd generation products: built upon the advances of the second generation, 3rd generation products use synergism by combining cellulases of different classes. Also, some non-enzyme additives that increase the activity rate of the cellulase are used. Increases
in the overall activity and speed of activity leads to lower end use costs. The 3rd generation enzyme products address the concerns of the previous two. Stability, specificity, purity and cost of use have all been improved. The following graphs show the value of using 3rd generation enzymes for strength development. The objective of this mill trial was threefold. The first objective was to increase strength with the existing furnish mix. Once this strength was achieved, the second objective to reduce refining was employed. The third portion reduced the amount of softwood in the furnish. This strategy is not uncommon. It is the process of how to achieve the strength that allows for additional benefits such as fiber mix changes. This mill was making a towel grade and was aiming for increased bulk. By achieving the strength target in a new way, using a 3rd generation enzyme, the additional bulk was gained as a result of the reduction of refiner energy and fiber mix changes. The
Buckman makes papermaking smarter. Because the smartest mill wins enzyme allowed this mill to keep the strength, increase hardwood usage and reduce refiner energy, leading to a bulkier (higher caliper) sheet. How strength is achieved determines what properties the base sheet will have. When 3rd generation enzymes are used to reach strength targets, sheet properties such as bulk, hand feel and softness can all be improved. When these enzymes are used for strength development the window of operation is expanding for the tissue manufacturer. Flexibility in furnish mix, refiner energy and other options not previously available are now viable options. When it comes to tissue manufacturing, not all strength is created equal. ●
BUCKMAN 1256 N. McLean Blvd. TN 38108 Memphis - USA ■ website: www.buckman.com
■■ With the addition of Maximyze® 2596, refiner energy was reduced and caliper was increased.
■ contact person: Mark Christopher ■ email: email@example.com
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■■ PSF’s mill in Mexicali houses six tissue machines. Valmet has delivered three Advantage DCT100TS machines and one Advantage NTT machine.
The art of maximizing production 30
Getting the most out of a production line in terms of capacity and paper quality demands requires the capability to run at high speed, reliable and efficient equipment, as well as the courage to push boundaries. Fabrica de Papel San Francisco has it all. by: Valmet
abrica de Papel San Francisco (PSF) in Mexicali, Mexico, has set the target of growing in line with the market. To meet the demand for capacity, they have invested in new tissue machines every three or four years. Most recent installation is TM7 an Advantage DCT machine from Valmet.
Full speed Investing is one thing, but the capability to get large volumes of high-quality paper out of the lines is something else. Running as fast as possible has been part of PSF’s strategy ever since the start-up of their first tissue machine. They have a continuous production speed many other can only dream of. Dario Palma y Meza, Operations Director, explains: “In all aspects, we want to get the most out of our equipment. The machine is designed for 2,200 m/min, our strategy is to run as close as possible to that level. To be competitive in the Mexican market, you need an efficient production process and qualified people. And you always need to be in touch with the latest trends, and what can give you the edge in manufacturing”.
TM 7 sets new record TM 7 follow this strategy. The start-up set yet another record, reaching 2,000 m/min within 48 hours - and it just continues! To execute a start-up in that short time means that a lot of things must work perfectly together. “This was the sixth tissue machine we started up, so one big factor is of course to utilize people’s experience from previous installations. We always use operators who are familiar with the process and the technology. Support from Valmet is important, as is a stable and reliable tissue machine with high efficiency. We had a really good start-up, and we have been running at full speed ever since”, Palma continues.
Pioneering in tissue production PSF is something of a pioneer in the tissue business. The company already set the world speed record back in 2009, and it was the first to start up an Advantage NTT machine. Today it produces high-value grades from virgin pulp on the NTT machine. “The NTT concept is great. It has given us the opportunity to enter the textured market. We are happy to have the capability not only to do textured tissue, but also conventional tissue at a high basis weight. Its drying capacity gives a very nice level of production that I haven’t heard of from any other machine”, says Palma.
High-quality tissue with low energy consumption “The Mexican market mainly requires 100% recycled tissue. The virgin fiber products are somewhere between five and ten percent of the market. So, our need was a machine that could provide 100-percent recycled, low-basis-weight bath tissue. Our philosophy is also to go for low energy consumption and the lowest possible emissions. So we decided to go for an Advantage DCT machine with an Advantage ViscoNip press to achieve the best tissue quality combined with the lowest energy consumption”. explains Palma. The ViscoNip press is a new technology for the mill team in Mexicali. But they are comfortable with the process and find it easy to handle. “The machine is running very well, and we are mainly utilizing low and medium nip loads to get more caliper and softness. ▲▲Dario Palma y Meza, Operations Director.
Valmet’s vision is to become the global champion in serving its customers Running at 2,150 m/min in daily production is not a problem, and we have even hit speeds of 2,200 for several days. We have also seen savings in electricity”, says Enrique Zarate, Mill Manager.
Trust and teamwork uuEnrique Zarate, is happy with the ViscoNip press: “It’s the best choice for the grades we need to produce”, says Zarate.
VALMET - SWEDEN, ITALY AND USA ■ website: www.valmet.com ■ phone: +46 54 171000 / +39 0481 528311 / +1 207 2821521 ■ email: firstname.lastname@example.org
PSF and Valmet have a long-term relationship with Valmet, continuing. “A good supplier becomes a part of our team. It’s very important to have a responsible crew you can trust and be open with about problems or challenges, a team that makes all the effort to solve any issue. It makes life easier for all of us”, Zarate continues. With TM 7, the Mexicali mill will reach a daily production of 500 tons, considering they run a high percentage of very low basis weight. Their market share in Mexico is currently 18 percent, with a target of continued growth. Next machine will start-up during 2020 and with skills, dedication and expertise, they will hold on to the need for speed. ●
Up to the finished roll:
FUTURA moves boundaries again in tissue converting
Futura SpA is widely regarded as the technological leader in the tissue converting segment. Its latest innovations which reach as far as the finished roll have asserted its reputation. by: Futura SpA 34
FuturaLab is the beating heart of innovation at Futura. This is where it all happens
ere is the summery: “With Together - the result of Futura’s technical partnership with Plusline Srl - Futura makes good on its promise to introduce extraordinary innovations which reach as far as shelf-ready packs of tissue; then there is the JOI embosser, taken to a new level of automation and performance in its latest incarnation; automatic adjustment of the rewinder is yet another step to optimise output without manual intervention; and automatic blade-changing on the log saw including bevel measurement is a fresh victory for safety and efficiency. And now the detail…
Together to the shelf-ready pack
Together is a highly automated, integrated system which can be installed downstream of any existing or new converting rewinder line, not necessarily produced by Futura, thus opening opportunities both for setting up new plants, and for making existing lines much more efficient. Together includes log trimming, log cutting and integrated packaging, all in one line, guaranteeing a continuous flow of product from converting to packaging. The optimised layout lowers the risk of product damage because of reduced handling. It is ready to be viewed in action at FuturaLab. The integration of Together in a Converting line allows tissue producers to optimize use of space. The compact layout of Together brings a drastic
▼▼Automatic change of embossing rolls with the Andromeda System.
▲▲Futura Chief Technology Officer Giovacchino Giurlani.
FUTURA SPA Via di Sottopoggio 1/x 55012 Guamo (LU) - Italy ■ website: www.futuraconverting.com ■ phone: +39 0583 94911
reduction in footprint of up to 60 sq m for each line, which also allows more lines in the same premises. Thanks to the high-level automation, reduction in components and the simplification of the production line, Together also makes management and maintenance of the line easier, reduces energy consumption and the number of operators required. The simplification and shortening of the line, the reduction in the number of components (including the lack of chocke belts), and the quality of the materials used guarantee the continuous flow of product with no deformation, and at higher speeds. The fact that it is enclosed yet accessible ensures operation and maintenance are far easier and guarantees operator safety. At the same time, users can expect better folds, and a sealed and closed pack makes for a more hygienic, better protected finished product. JOI for the 2020s. The JOI news includes a complete revision of the transmission system of the embosser. Embossing roll changes are of course handled by the Andromeda crane including the rubber rolls, cliché and anilox. Combined with a new storage area for embossing rolls, which is fully accessible in complete safety while the line is running, it takes JOI to a new level of automation - even to the oil circulation system detachment which is managed from the control panel. Forward with the rewinder. Automatic adjustments on the Sferica rewinder set a new standard for the industry. More than just a camera, the vision system on Sferica measures the position of the log during winding, calculates any error compared with the ideal situation and automatically sets the winding parameters. A virtual operator that is continuously supervising the production parameters, adjusting them and then if necessary triggering alarms before producing waste. Critical log saw innovation. Automatic blade change on the log saw is another game changer enhancing the safety of the operators. Furthermore combined with the unique, patented trim removal system, which is critical to the success of the Together innovation, and the log saw/bevel measurement system that enables full operation ensuring the quality of the product, maximising productivity. Thanks to a camera monitoring system to analyse the blade’s condition while it’s running, automatic blade grinding is adjusted as needed. This system keeps the blade in optimum cutting condition without disrupting production and without unnecessary grinding. A curious market. “The market is always curious but cautious about innovations, which represent a major departure from standard solutions”, says Futura Chief Technology Officer Giovacchino Giurlani. “The fact that the validity of Together was confirmed so soon after its launch with two orders was a welcome affirmation of this cutting-edge technology. Our embossing, rewinding and cutting developments meet the same desire in the market for increased automation and we anticipate a very positive response.” ●
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fired up its th 200 TT SYD Toscotec has successfully started up its 200th Steel Yankee Dryer at César Iglesias Group’s mill in Santo Domingo, by: Giulia Fabbri, Toscotec SpA Dominican Republic.
■■ Toscotec’s Your Expert Service (YES) is highly specialized in TT SYD checks and maintenance.
■■ Toscotec’s 200th Steel Yankee Dryer departs from TT SYD Technology Center in Massa (Italy) to César Iglesias Group’s mill in Santo Domingo.
ésar Iglesias Technical Director, Jesús Feris Ferrús, commented: “Following three months of stable operation, we can confirm that our new steel Yankee dryer is delivering exceptional performances. We registered a 25% reduction of our overall thermal consumption including Yankee and Hoods. The TT SYD’s drying capacity is so high that we could significantly decrease the hoods temperature, thereby saving a substantial amount of energy. We also witnessed a great improvement of our tissue quality, in terms of hand feel and CD moisture profile. This led to an increase in our converting efficiency, which we estimate to be in the range of 10%”. Since the first TT SYD was started up in the year 2000, this breakthrough innovation has come a long way. Toscotec’s TT SYD was the first Yankee dryer made of steel to come to the global market and it has since outclassed cast-iron Yankees to become the new technological standard of the tissue industry. Since then, TT SYD has had numerous imitation attempts, but none has reached its superior level of performance and the service experience which makes Toscotec the leading manufacturer of steel Yankee dryers worldwide. With over 220 TT SYDs sold around the globe, Toscotec is by many magnitudes the world leading manufacturer of Steel Yankee Dryers; 200 cylinders currently operating all over the
▼▼Toscotec Steel Yankee Dryer TT SYD.
world is a notable milestone. These TT SYDs are running efficiently in more than 40 different countries across 5 continents, including over 110 cylinders in Asia and over 50 in Europe. The US market has only recently opened up to steel Yankees, and TT SYD sales have already reached over 10 units. Out of the top 12 tissue producers in the world, 10 groups have recognised TT SYD’s superior energy efficiency and performance, and installed it at one or more of their production sites. These producers include Essity, APP, Hengan, Sofidel, WEPA, CMPC, Kruger and others who remain confidential. Last year, Toscotec’s research and development launched the TT SYD’s third generation design. The first and second generation had been developed and continuously improved in 20 years of ongoing research, monitoring, and service of steel Yankees operating under
very different conditions all across the globe. This accumulated expertise allowed for the development of TT SYD’s third product upgrade, where the height, width, and pitch of the internal ribs, as well as the shell thickness, attain an optimal geometry to maximize heat transfer efficiency without compromising safety or longevity. Toscotec’s R&D is also focusing on new innovations, including the Defender®, an internal surface treatment that ensures extraordinary resistance against corrosion and erosion. TT SYD’s operation stability, durability, and correct safety coefficient are all guarantees
Excellence in technologies applied to every customer’s need. Everywhere, every day, for over 65 years of its safety. Moreover, in order to optimize the manufacturing process and shorten the delivery period, in 2012 Toscotec set up a manufacturing space specifically dedicated to the construction of its Steel Yankee Dryers. TT SYD Technology Center is a highly technological and fully integrated 5,000 m2 plant, located just a few kilometers away from Massa’s maritime port, offering the logistical advantage of ensuring easy access to the seaport for large diameter Yankees. Finally, beside TT SYD design advancements, Toscotec Service team has progressively and continuously upgraded the quality and accuracy of its Yankee dryer services, by relying on Toscotec’s extensive experience - the longest in the tissue industry - of steel Yankee engineering design, manufacturing, and service, in order to achieve optimal performance and infinite life. ●
TOSCOTEC SPA Viale Europa 317/F 55012 Marlia (LU) - Italy ■ website: www.toscotec.com ■ phone: +39 0583 40871 ■ contact person: Giulia Fabbri ■ email: firstname.lastname@example.org
Renovaâ&#x20AC;&#x2122;s Moviroll roll pushers are the result of continuous research and development based on customers feedback and their experience on field. by: Renova Srl
the solution for safe material handling
■■ An operator moving a tissue roll with MRE LPT.
he technical standard ISO 11228 “Ergonomics - Manual handling” part 2 “Pushing and pulling” specifies the risks and the recommended limits for pushing and pulling activities carried out by an adult worker in an upright position, who applies force with both hands to move or stop an object. It takes into consideration a series of variables, such as strength, posture, distance travelled, characteristics of the object, individual characteristics of the operator, work organization and thus allowing to evaluate the health risks for the workers deriving from manual transport. In general, manual handling of loads, representing a potential danger for workers, should always be avoided. All the more reason, if the recommended limits are exceeded, measures should be taken to avoid performing the task manually. In tissue industry it happens to see operators moving manually the rolls across the plant. Sometimes there’s just not enough space for forklifts or other material handling systems to move freely. Renova’s Moviroll roll pusher allows the operator to effortlessly and safely manoeuvre both large and small rolls on a flat surface where forklifts and other systems cannot operate. As it allows agile handling of rolls it saves time for other activities, thus improving the productivity in the plant. Every year a wider range of models plus a range of optionals and accessories are available, all of them designed, manufactured and assembled on site at Renova, in Italy.
Renova: from 1960 pneumatic brakes and web tension control systems
▲▲Moviroll’s battery on-off button and status led.
▲▲Detail of the battery status LED.
MRE LPT, DESIGNED FOR TISSUE ROLLS All application needs are different, that is why Renova offers different design models of battery powered roll pushers. Being specifically designed for the Tissue industry, MRE LPT has an oversized roller that prevents damages to soft materials. It can move reels up to 20 tons and with a diameter of 4.5 meters without any effort by the worker and in total safety, by eliminating possible injuries caused by manual pushing. All models are managed by TUV -ISO 9001.
HIGH PERFORMANCE, LONG LIFE SERVICE Moviroll is equipped with a 24 V lithium battery which powers the 24 V DC IP 44 motor. This system ensures the operator to move about 60-120 rolls with only one battery charge, equal to 3-5 shifts, offering the advantage of free movement without the constraints of the pneumatic connections. The battery status LED warns when the battery needs to be recharged while the on/off button preserves the battery charge without the need of removing the battery. The Plug & Play batteries allow to change the battery in less than 10 seconds, without having to interrupt operations, whilst recharging the battery does not take more than 4 hours. A lithium battery life span is numerable to 500 recharges and is guaranteed by a 24-month warranty, applied also on Moviroll. Moviroll is a pioneer among material handling systems because it is
▲▲Rotating Plate, Moviroll’s accessory.
eco-friendly: the lithium battery is completely free of any polluting substance and therefore safer for the operator and the environment.
ACCESSORIES In addition to being moved in a straight line, the reels might need to change direction without compelling the worker to use brute force in order to rotate it. Thinking about the operator safety,
Innovative solutions that increase productivity and safety level, while reducing maintenance costs and procedures
▼▼Moviroll MRE LPT.
Renova also offers a wide range of accessories. The Rotating Plate is the accessory specially designed within the Moviroll line for rotating 3600 cylindrical loads. Moviroll can lift the roll onto Rotating Plate and then discharge it after the rotation in the correct position. With a load force of 7 tons, this plate helps in the everyday operations in the plant. When it comes to people safety, Renova is always on the front line to design innovative solutions. ●
RENOVA SRL Viale Rimembranze 93 20099 Sesto San Giovanni (MI) - Italy ■ website: www.renovainnovations.com ■ phone: +39 0227007394 ■ email: email@example.com
■■ A.Celli iDEAL Forged YD.
A.Celli Paper: together towards tomorrow
■■ A.Celli iDEAL Tissue Machine.
A.Celli Paper has a long experience in paper and tissue paper machinery and equipment market, offering advanced solutions for complete turnkey plants, tissue machines (manufacturing and rebuilding), winders and rewinders for tissue, paper and cardboard (manufacturing and rebuilding), by: A.Celli Paper SpA handling and packaging. 46
.Celli Paper handles engineering and equipment, as well as assistance with assembly and commissioning of the machinery and training of customer’s staff. “One source, one responsibility” is the company motto, expressing the commitment of A.Celli Paper to work in partnership with the customer, providing an absolute guarantee.
The company’s core business starts from Engineering & Process, with customized design and with a focus on final product quality, energy savings and efficiency. A.Celli Paper develops its iDEAL® Tissue Machines with the most advanced technologies and manages them by intelligent and sophisticated software, internally generated, guaranteeing maximum performances, according to the customer’s specific needs.
The range of iDEAL® models supports speeds up to 2,000 m/min, web width from 2,850 mm to 5,600 mm, and nominal production capacity up to 260 t/d, using virgin fibre, recycled paper and bamboo. A.Celli tissue machines are based on crescent former technology and feature a headbox of exclusive design. The patented X-Roll® system is energy efficient and can increase dryness after the pressing phase, preserving
■■ A. Celli - E-WIND T200 - Tissue Rewinder.
We design and supply high-end machinery and technological solutions for the global market of paper and nonwovens the bulk of the paper, as a user friendly alternative to the classic shoe press. A.Celli has also designed the exclusive and patented FORGED YD® Yankee, with no welds and with bolted heads, ensuring greater resistance over time and less maintenance. The final part of the tissue machine is the pope reel with centre winding technology, maintaining web tension to improve winding and increase the overall efficiency of the machine. In the last years, also A.Celli E-WIND® Tissue & Paper Rewinder have changed their look, thanks to an innovative design that, moreover, guarantees maximum safety and ergonomy for operators. A special tension control system reduces the loss of bulk during winding, even at high speeds, guaranteeing superior performance and high quality of the final product. A Slittomatic® cutting system, controlled by a new generation of software, allows maximum performance and safety. The paper rewinders handle web
widths up to 8 m and work with drive speed up to 2,600 mpm. A.Celli completes its product range with its R-WAY® Integrated Solutions, able to manage and optimise the Roll Handling & Packaging processes, from preparation to storage, up to the shipment of goods: conveyors, elevators, wrapping machines with single or double arm and automatic guided vehicles. AGVs offer extremely advantageous solutions for the management of automated warehouses which, today, are dynamic and intelligent environments: besides space optimization, higher speed, precision and safety are achieved, eliminating human errors. Furthermore the innovative iREEL® technology plays an important role as a sort of “data passport” of each single paper reel, allowing its classification and traceability by simply reading and storing the relative data during both production and subsequent converting phases. Extreme Automation is the business unit of the A.Celli Group, entirely dedicated to the development
of software solutions for machine data management, analysis and control, from the perspective of Industry 4.0. This highly specialized software division has improved machine learning and dialoguing technologies for global integration of the entire production line, to implement predictive maintenance and optimisation of the working parameters of the machineries. The new “smart” machines are able to monitor, analyse, store and process data, providing optimal solutions aimed at improving product quality and the production cycle, while reducing downtime, human error and consumption. A.Celli offers its customers and its business partners a prompt assistance and a long term collaboration by its A.Celli 2-CARE®, the customer service division, a skilled and efficient department in continuous evolution, handling upgrading and retrofitting activities of tissue machines, winder and slitter rewinders both for tissue and for paper, as well as after-sales assistance and the supply of spare parts. ●
■■ A.Celli 2-CARE - Customer Service.
A.CELLI PAPER SPA Via del Rogio 17 55012 Tassignano (LU) - Italy ■ website: www.acelli.it ■ phone: +39 0583 98441 ■ email: firstname.lastname@example.org
Gambini America: ready to get in the game
Introducing the new team from Green Bay, Wisconsin. by: Gambini SpA
uuTeam Gambini America: from left, 1st Mr. Bart Drage; 3rd Mr. Gianni Gambini.
■■ The new Gambini America’s headquarters in Green Bay, WI.
he 2020 is not a common year, at Gambini. Beyond it being for everybody the start of a new decade - thus giving us all the opportunity to take stock of the ten years behind us and to begin imagining the ten ones ahead - it also marks this company’s foundation 150th anniversary. In 1870 Mr. Giovanni Gambini, today’s homonymous President’s great-grandfather, established a small cutlery-making workshop in Montecarlo, close to Lucca, just feet away from the current headquarters. Though there are many ways to pay tribute to the founder and his vision, Gambini chose to make what it’s best at: picking a challenge and putting in place every effort to make it happen. The one pertaining this year is a defining one, it is a complex operation Gambini has been thinking of for years, preparing itself for a long time: tackling the US market, going to America to play in the major league of converting, instituting an all-American brand-new company. And from 2020 Gambini America has a new headquarter, built from scratch in Green Bay, Wisconsin, to accommodate its US-based Team America. Being at the heart of one of the biggest paper districts in the world, Gambini’s people can now operate from what is considered as a strategic site for North, Central and South America. In just a few months of activity, Gambini America has already reached remarkable results, providing after-hours emergency support to its customers and bringing off 32 installations. Since its inauguration, Gambini America has been working with a team of highly competitive and skilled pros, led by Bart Drage, Managing Director, and with the unique support and knowledge of Gianni Gambini, the fifth generation of Gambinis. Mr. Carlo Berti, Gambini’s Sales Director, likes quoting a notorious TV commercial from some years ago, featuring Clint Eastwood: the actor is seen urging the American people to take pride of themselves and get together as one. Also Team Gambini America considers itself as if they were in the locker room - the first half just over - during the halftime pause.
Airmill, the best tissue rolls with less resources
▲▲Mr. Carlo Berti.
▼▼One of Gambini’s plants, in Italy.
Today, all that matters to Mr. Berti and his people is what’s ahead: the second half, about to begin! As evocative as it sounds, this ideal picture describes correctly Gambini America’s situation: an All-Star team - the best technicians in town - ready to take the pitch and get in the game. Besides, the industry knows very well what Gambini’s done and keeps doing: beyond AirMill - the greatest game-changer in the converting field in years - they’ve concentrated their efforts on a new professional rewinder, with just one focus in their mind: making user-friendly and money-saving lines. Mr. Berti says they prefer thinking in terms of 10-year time spans; as we were writing at the beginning of this article, a new decade is coming, so: how would we all want our future selves to think of the Twenties, ten years from now? What do we all think the industry needs machinery-making companies - as Gambini is - to do, to change the future and not just live it? The result is the converting line of the Twenties, which consumes less energy and less raw material. As simple as that. Gambini thinks of values, rather than features; and customers know what they need, they ask for it very clearly. Just one single request: Make me as recognizable as you can! Which translates into: Let me produce something unique, that nobody else can. It’s a giant strategic leap, as no one wants to feel one among thousands. And to make customers happy, what Gambini - and its competitors - would need to do is providing that ability to their customers: no magic, just careful design and love for what they do. Gambini and Gambini America are ready; and the industry is going to hear from them! ●
GAMBINI SPA Variante via Romana 9 - Badia Pozzeveri 55011 Altopascio (LU) - Italy ■ website: www.gambinispa.com/en/ ■ phone: +39 0583 2776 ■ contact person: Nicola Romagnani, Marketing Manager ■ email: email@example.com
IN LINE WITH YOUR PRODUCT During the last 40 years, MacDue Impianti has provided complete solutions including manufacturing, assembling and the installation of automatic packaging machines. Innovation, training and more than 7,500 units sold worldwide are the key points of a dynamic team capable of responding to every market need. What we supply: - Complete lines “from log saw to the end of the line” - Palletizing islands for consumer and industrial products - Case packers with the most competitive price on the market - Vision systems to monitor the line’s performance and detect issues - Native language on-site technicians to support our customers
Digital enablers at Sulzer. Smart and connected equipment
Sulzer uses cloud platforms, digital connectivity and state-of-the-art mesh sensor technology to create added value to the customers. by: Sulzer Pumps Finland Oy
ulzer is developing and launching a series of digital solutions to support the core business model of selling new equipment, services and retrofits. The company uses digital tools to turn its products into smart devices, allowing customers to have valuable insights into the equipment data. As digital sensors are becoming cheaper and more equipment is connected to the Internet (Internet of Things, IoT), there is an enormous potential to convert data from the devices into actionable business insights. This can be translated into optimized predictive maintenance and maximized uptime of the process in question. Today, the technology involved is becoming more affordable. It is easy and cost-efficient to deploy for new equipment or to retrofit in existing installations. This is particularly attractive in general industry, such as pulp and paper mills as well as the sugar, food, and fertilizer industries, where configured pumps have traditionally not been equipped with such options.
Sulzer Sense for wireless condition monitoring Sulzer recently took the next step in digitalization by launching a wireless IoT condition monitoring system, Sulzer Sense. The solution includes wireless sensors that can be attached to a pump, agitator, motor or any rotating equipment - regardless of the type or brand, and in all industries. The sensors measure temperature and vibration and send the data to the cloud. This means that the operating status of the equipment can be remotely monitored 24 hours a day, seven days a week through Sulzer’s online service. No manual measurement is needed. Sulzer’s online service is a cloud-based platform. It is easy to use and offers various
■■ Wireless sensors attached to the equipment measure temperature and vibration in three axis and send the data into the cloud service via a gateway.
▲▲Sulzer Sense installation at a customer site. uuSulzer Sense wireless IoT condition monitoring sensor.
value-adding services. The customers have secure access to the latest equipment data and related services, as well as technical product documentation and drawings. With the service, it is possible to track the condition of the product, view the equipment trend data, identify spare parts, check spare parts availability, place an order or view the order status. Sulzer’s online service helps to increase productivity, efficiency and cost savings by automating information sharing processes.
Wireless IoT condition monitoring saves time and money - and is safe Sulzer Sense devices are battery powered and they operate in a wireless mesh network. The cloud-based solution is secure, and no software installation is required. Also, the wireless sensors and the gateway are easy to install and use - just plug and play. Continuous condition monitoring enables the identification of possible problems in the process. Manual measurement on the site is not needed. This makes monitoring safe because the maintenance personnel do not have to access installation areas that might include a safety risk. Instead, they can allocate their time to more productive
▲▲The Sulzer Sense condition monitoring system is compatible with all types of rotating equipment.
Our customers benefit from our commitment to innovation, performance and quality tasks. The system is convenient because the measurement values and trends of the equipment are available anywhere and anytime in Sulzer’s online service via laptop, mobile phone or tablet. If the set temperature or vibration limits are exceeded, the operator sees an alert in the cloud service. Sulzer’s goal is to deliver its new process equipment with the integrated sensor so that the customers can benefit from the new technology. Sulzer Sense has been running at test sites for a few months now. It helps the operators identify process problems by just measuring vibration and temperatures. By combining measurement data from Sulzer Sense with other existing data, the customers have been able to improve their processes. ●
SULZER PUMPS FINLAND OY P.O. Box 66 FI-48601 Kotka - Finland ■ website: www.sulzer.com ■ contact person: Sami Saarenvalta, Development Manager ■ phone: +358 50 526 2603
▲▲Sulzer Sense gateway.
■ email: firstname.lastname@example.org
Profitable Solutions For Paper Industry
like no other
watch me !
Global Connecting over 5000 installations
• • • • • • • • • •
Y a n ke e h o o d co m b o a i r syste m Re co ve r y b o i l e r Mist & Dust removal system Ha l l V e n ti l a ti o n S te a m & Co n d e n sa te syste m Ro ta ry j o i n ts Y a n ke e h e a d i n su l a ti o n Felt & Wire cleaning system W a te r fi l te r
Via del Mulino 24 - 55015 Montecarlo - Lucca - Tuscany - Italy
• • • • • • • • • •
phone +39 0583496040
E d g e tr i m T a i l cu tte r B a si s w e i g h t va l ve Q CS Y a n ke e co a ti n g sys tem Do cto r o sci l l a to r s S p a r e p a r ts S h a ft P u l l e r s E xp a n d a b l e sh a ft Ha n d l i n g S yste m
fax +39 0583496721 email@example.com
Officine Airaghi: maximum durability and reliability. Customized quality design For Officine Airaghi being a supplier means being able to offer a service and a specific technical advice to its customers. In fact, it is thanks to a strong sector specialization that it can remain competitive in global and globalized contexts such as today’s. by: Officine Airaghi Srl
ith its 70 years of experience in the stock preparation field, Officine Airaghi brings its clients a wealth of knowledge and the newest technologies for the production of spare parts such as discs and cones for refiners, spares for deflakers, screen plates (or sectors) for pulpers, sleeves for shafts, impellers and shafts, basket screens and much more. The experience acquired throughout this seven decades allows us to have a deep knowledge of technical and maintenance problems. The company can design and manufacture all spares parts for stock preparation machinery with a very quick turnaround.
Officine Airaghi product range Refiner spares. Officine Airaghi is able to supply
both disc and conical refiner spare parts for all brands on the market. All products are made using a MILLING CNC Machine, so the pattern (bar, groove, angle) can be easily modified and changed according to customer’s needs. For conical spares, we offer a wide range of moulds as well as milled solutions (CNConic®, internationally patented). The company can manufacture every common pattern and geometry required by paper mills machineries, such as short conical fillings with shallow angle (Conflo), low conical fillings with shallow angle (Jordan), short conical with large angle (Claflin). Deflaker spares. Officine Airaghi can supply all the most popular deflaker spare parts on the market (toothed rims or casted). In specific the company manufactures: drilled deflaker discs in stainless steel alloys thermally treated; toothed rims in stainless steel alloy thermally treated,
â&#x2013;˛â&#x2013;˛CNC turning machine.
from 270 to 950 mm diameter; deflaker monoblock castings in stainless steel alloys thermally treated. Additionally, it can manufacture deflakerâ&#x20AC;&#x2122;s parts based on new models and castings, if the paper mill requests it. Other spare parts. Officine Airaghi has a long history in the stock preparation field and has developed and manufactured other spares for many different machines and applications. In particular: basket screens with holes and/or slots in stainless steel alloys for any basket model and machinery; screen or pulper drilled plates
We design and produce various types of spare parts for stock preparation machineries
in special new alloys, with better performance than AISI 304; impellers and shafts in stainless steel thermally treated; sleeves for shaft protection in stainless steel thermally treated or with hard surface (ceramic, etc.).
Topic of interest: cellulose refining and role of appropriate milling components The refining process can be considered as one of the most important stages in the paper production using cellulose as a raw material. As a matter of fact, refining can be considered as the only process in the whole paper mill system in which fibers are physically modified, to reach the right balance between flexibility and bonding capacity. The choice of the most appropriate refining intensity is fundamental and is dependent on the selection of a spare part that can optimize energy consumption and obtain the best results for the final product.
ttEFP discs installed on refiner.
uuAiraghi IQ Screen basket.
finishing obtained by the use of CNC machine tools make the perfectly perpendicularity of bars and grooves and the consequent reduction of friction and of energy consumption possible. This will translate in maximizing the hydraulic capacity and the refiner efficiency maintaining constant values through the spare lifetime. Another key factor is the consistency of refining parameters set up. All milled fillings made by Officine Airaghi maintain the bar and groove dimensions, throughout the entire filling lifetime. In fact the bars in our spares will maintain their rectangular section independently from wear while castings filling will not.
Our mission: competency, quality, reliability, precision, punctuality Customized precision with milling technology Officine Airaghi has developed a specific manufacturing method for achieving this result: the milling technology. Thanks to the milling technology it is able to design and produce spare parts specifically tailor-made for each customer, without any fabrication restriction in realization, which is not possible with traditional methods like casting, fabricating and welding. Paper mills can choose among an infinite range of solutions and combinations of geometries, patterns and sizes with the warranty of a constant fulfillment of characteristics (both of fillings and fibers) throughout the lifetime of the spares. The milling technology is the only solution that allows extreme customization because of the precision in execution of the new generation numerical controlled machines (CNC). The attention for details and the accurate fillings
▲▲Turning operation on a disc refiner spare.
Officine Airaghi offers its clients a complete and very high quality service, from the design customization and specific technical study, to the manufacturing and final execution and delivery of spare parts. The delivery time is prompt and fast, typically they can manufacture a spare in less than 30-40 working days (EXW). All Officine Airaghi quality standards are guaranteed by the Certification UNI EN ISO 9001:2015. ●
OFFICINE AIRAGHI SRL Via Garofoli 239 37057 San Giovanni Lupatoto (VR) - Italy ■ website: www.officineairaghi.it ■ phone: +39 045 545674 ■ email: firstname.lastname@example.org ■ contact person: Michele Ghibellini, Export Manager ■ email: email@example.com
Key equipment: the case for conventional thinking ANDRITZ is regarded as an innovator in developing technologies for the manufacture of premium tissue grades that are in high demand today. Yet the majority of the world’s tissue is produced using conventional dry-creping techniques. To serve this large market, ANDRITZ continually enhances the reliability and performance of its “standard” technology. by: ANDRITZ AG
ttANDRITZ Papillon refiner with its compact cylindrical rotor design.
NDRITZ has long recognized the importance of this foundation and has built upon it. ANDRITZ has invested a great deal of R&D work - with the inauguration of the pilot plant in Graz - in the development of new technologies for the production of texturized and TAD paper grades. Nevertheless, ANDRITZ also recognizes the importance of the conventional tissue machine, which is still a highly engineered machine worthy of respect.
Full line of dry-creping solutions Today, ANDRITZ is among the top three tissue technology suppliers in the world and the number one supplier in China, where it all began with the first tissue machine at Hengan - the company now operates 13 ANDRITZ machines. Further installations have taken place at almost all major Chinese tissue producers. With this solid foundation, the company continues to improve the performance and cost-efficiency of its dry-crepe product technologies PrimeLineCOMPACT and PrimeLineTM which are available in a variety of widths and capacities: PrimeLineCOMPACT machines are ideal for producers who
■■ ANDRITZ is the number one supplier of tissue machines in China, where it all began with the first tissue machine at Hengan - the company now operates 13 ANDRITZ machines.
Your technology and service partner for the production of pulp, paper, tissue, and board appreciate a standardized, modular approach that reduces engineering, transport, infrastructure, installation, and start-up costs. The COMPACT machine ensures a certain throughput and production quality in a streamlined, cost-effective package. PrimeLineTM machines are customized high-speed machines with widths from 2.6 to 5.6 m. Like the PrimeLineCOMPACT, they can be equipped with a shoe press, a steel Yankee (diameters up to 26 ft) and ANDRITZ Novimpianti air and energy systems that help to improve yield, efficiencies, and energy conservation. Proven ANDRITZ technologies in stock preparation, such as ShortFlow approach technology and the Papillon refiner, contribute to the economical use of resources and superior performance in conventional tissue applications. ShortFlow minimizes the amount of equipment and the amount of energy consumed, saving on both capital and operating costs. It requires very low, but efficient, storage volumes to reduce the size of tanks and allow for fast grade changes on the machine. For refining, the Papillon refiner has a compact cylindrical rotor design. Energy savings can be quite significant when compared to competitive refiners,
■■ MEET OUR TISSUE EXPERTS. Our tissue experts, their know-how,passion, and excitement, are what make the difference for our customers when it comes to best-in-class tissue technology, production equipment, and service. Get to know Erwin Walcher, ANDRITZ Senior Sales Manager, with more than 40 years of experience in the tissue business.
■■ 1 PrimeFlow 1-, 2-, or 3-layer for excellent formation quality
■■ 6 ■■ 8
■■ 2 PrimeFlow CrescentFormer, TwinWire former
■■ 7 ■■ 9 ■■ 2
■■ 3 PrimePickUp To improve runability ■■ 4 PrimeDry Heat Recovery Bringing energy back to production - up to 25% steam saving
■■ 6 PrimeDry Hood Gas- or steam-heated, cogeneration gas-fed heated hood, combined efficiency hood (wet blowing, dry suction)
■■ 7 PrimeDry Steel Yankee The giant for efficient drying - up to 10% better performance
■■ 5 PrimePress XT Evo Energy-efficient shoe press - up to 48% post-press dryness
■■ 8 PrimeDustEXT Dry or wet dust removal for clean environment conditions ■■ 9 PrimeReel Standard, advanced, and centerwind
and the fiber is properly treated over the entire refining area. One of the more recent innovations in stock preparation, the PrimeScreen X, improves energy consumption, screening efficiency, and ease of maintenance. This new screen has a top feed stock inlet and a new PrimeRotor configuration with new rotor foils to offer unique benefits. Machine and mill automation are addressed through ANDRITZ Automation’s Metris technologies for digitalization, simulation and overall optimization. SmartSolutions for tissue producers include, but are not limited to, automation technologies for predictive maintenance, the Metris UX Platform, Metris Smart Service including the Metris Spare Parts Catalog and Metris OPP (Optimization of Process Performance).
Innovation and performance To further develop and support its technologies, ANDRITZ continues to make investments in the PrimeLineTIAC. The tissue pilot plant is available to all tissue producers and suppliers worldwide, and also to partners and institutions within the tissue value chain. For example, the latest machine design, PrimeLineTEX, was developed and tested at the tissue pilot plant. It enables the production of premium textured tissue with a quality very close to TAD. The PrimeLineTEX tissue machine is of utmost flexibility: it can be configured as a “pure” textured machine or as a machine that can produce either dry-crepe or textured tissue. ●
ANDRITZ AG ■■ ANDRITZ high-performance PrimeDry Steel Yankees are made entirely of steel, contributing to enhanced safety and 8-10% better machine performance when compared to a cast Yankee.
Stattegger Strasse 18 8045 Graz - Austria ■ website: www.andritz.com/tissue ■ email: firstname.lastname@example.org
■■ MARE RD lab in Ossona.
as a partner to approach Halogenated Organic Compounds Management in tissue making by: Mare SpA
ear TissueMAG Reader, MARE is back on TissueMAG pages to introduce its capabilities in the field of Halogenated Organic Compounds (HOC) assessment and management. Halogenated Organic Compounds have become a matter of concern in the latest years for many industrial fields, papermaking being one of those, as they have been indicated as possible precursors of mutagenics. The chemical categories in which they fall are today well known, namely AOX (Adsorbable Organically bound Halogens), that is HOC which can be absorbed on activated carbon, EOX (Extractable Organically Bound Halides), that is HOC which can be extracted with a non-polar solvent and POX (Purgeable Organically Bound Halogens), HOC which can be purged in the gas phase under defined conditions with an auxiliary gas. AOX is by far the most common category in many industrial fields as it is in Papermaking and Tissuemaking. Inside AOX, the substances of highest interest for Tissue are the well-known 1.3-dichloro-2-propanol (1.3-DCP) and 3-monochloropropane-1.2-diol (3-MCPD),
generally referred to as DCP and MCPD. Recommendation BFR XXXVI for the production of paper for food contact defines the maximum residual quantities of these substances to be found in paper and tissue. As DCP and MCPD are typical byproducts of wet strength resin productions, a lot of effort has been put by the producers of Wet Strength Resins to reduce their quantity in the product mix. Nowadays we can supply our customers with Wet Strength Resins allowing the production of tissue fulfilling BFR indications. Anyway, we have been observing, lately, that some of our customers would anyway report a significant residual of Halogenated Organic Compounds in their finished products. Investigating more deeply the situation, we came together with them to some surprising (although not so much) conclusions. In collaboration with a group producing Premium Tissue grades on the market, an extensive survey was done collecting various process parameters and correlating them with AOX values obtained in relevant paper samples. This was made possible by the full assembly of equipment (Picture 1 and Picture 2) to measure HOC available in MARE laboratory and the
From Paper and Board to manufacturing as a whole 67
▲▲ Picture 1: Detail of the double furnace technologies AOX analyzer with automatic sampling system.
▼▼Picture 2: Automatic adsorption unit for preparing samples for AOX determination according to the column method.
expertise accumulated in the latest years by our personnel, allowing the assessment of the said data with high reproducibility. Results are shown in Picture 3. As you can see, while the correlation between the AOX residue and the dosage of WSR is poor, a much more fitting correlation can be done found with the dosage of other process aids. In particular, we observed that, in this case study, AOX residual on paper was linked to two different aids, one in the wet end and one in the dry. Based on this, the substitution of the specific additive with other ones not containing AOX was suggested. In other case studies, a correlation between AOX residuals and different process aids was done, leading
to different suggestions to the customer, while, in some additional case study, a correlation between the use of specific raw materials in the furnish was and AOX was highlighted. During the completion of the aforementioned case histories, the results of MARE laboratory were compared repeatedly with the ones released by accredited independent European laboratories. It was definitely shown that the “numbers” were overlapping, showing to our customer the reliability of MARE measurements. MARE product portfolio is well integrated with all the products needed to achieve a minimization of the AOX residuals in tissue. Actually, a part of these additives has already been made available and used in years by our customers both in the wet and dry end of the machine, but only lately their importance has been re-discovered as a toll to control AOX in tissue paper, due to the growing interest in this topic. Dear TissueMAG Reader, in case we have caught your attention with this paper, please contact your local MARE sales rep in order to discover more. Thanks for your attention, MARE GROUP. ●
▲▲Picture 3: This picture shows some dispersion graph showing variable levels of correlation between AOX values and dosages of chemicals.
MARE SPA Via Verdi 3 20010 Ossona (MI) - Italy ■ phone: +39 02 903261 ■ email: email@example.com - firstname.lastname@example.org
Overcoming frontiers: optimized tissue pressure roll position with
SchäferRolls tisQ.R cover Application example WEPA Hygieneprodukte GmbH Marsberg-Giershagen, Germany. by: Frank Kretschmer, Product Manager SchäferRolls GmbH & Co. KG
■■ Pic. 1 - Suction press and nip roll position of PM 7.
roduction of tissue products is one of the most sophisticated processes in the paper industry. Very low basis weights, often produced at operating speeds of far above 2,000 m/min, dried in less than one second pass through a range of creping, reeling, rewinding, and converting processes. Only when these challenging demands on designers and operators of tissue manufacturing and converting equipment have been met, is the packed final product ready for delivery. But the difficulties don’t end there. Tissue manufacturers are faced with increasing demand for more efficient use of resources and cost effectiveness in production, without affecting product quality. As the pressure to enhance machine performance intensifies, hand-in-hand with the desire to meet customer quality standards, this drives continual efforts to optimise tissue product manufacturing. The choice of roll cover plays a significant part in the manufacturing process, as it directly affects the dewatering performance and the runnability of the equipment as well as the bulk and softness of tissue products. In times of growing cost and performance pressure, it’s more important than ever to select the right roll cover - one which best fulfils the specific demands of the manufacturing system and machine operator.
Pressure roll position - a real challenge Drying the tissue paper web with the heated Yankee cylinder and the hot air hood is an extremely energy-intensive process. Considering the constant growth in energy costs, all efforts are made to reduce energy consumption by enhancing mechanical dewatering. An increase in dry content after the pressing process has an immediate impact on reduction of energy costs and a resultant increase in system efficiency when producing tissue paper. Suction pressure and pressure rolls are expected to dewater the paper web as efficiently and gently as possible. Yet the roll covers are used in very difficult operating conditions, creating certain challenges defining the optimal nip geometry of the roll covers, primarily due to the extreme diameter/length ratio of the Yankee cylinder, the related dynamic deformation of the cylinder under internal steam pressure, temperature and linear loads. Low roll diameters and high operating speeds witnessed in
▲▲tisQ.R, view tender side.
▲▲tisQ.R, infrared image.
■■ Pic. 2 - WEPA Marsberg-Giershagen, Germany.
SchäferRolls is a leading name in the industry, renowned for its precision, technical expertise and solid track record modern tissue machines result in high linear loads and nip frequencies. As a consequence, the roll covers are exposed to extreme thermodynamic loads. Compared to suction pressure rolls, pressure rolls face substantially higher loads. Since there is no water flow to regulate the temperature for tissue pressure rolls, this leads to an increase in self-heating in the roll cover due to high nip frequencies and increased internal friction, which can quickly result in material fatigue in case of lack of cooling.
Tough and reliable: WEPA has overcome frontiers with the tisQ.R roll cover WEPA Hygieneprodukte GmbH was originally founded as the trading company, “Westfälische Papierfabrik“, in Arnsberg, Germany, in 1948. In 1953 the company expanded to become a manufacturing plant and since 1958 the WEPA Group has enjoyed international success in its core business of producing tissue paper. The company operates 22 paper machines and more than 90 processing machines for rolled and folded tissue paper products at locations in Germany, France, Italy, Poland, Netherlands and Great Britain, achieving a market share of approx. 8% (25% in Germany). Four paper machines are operated at WEPA in Marsberg-Giershagen (Pic. 2), on which toilet paper and kitchen towels are produced. The PM 7 produces toilet paper and is equipped with a suction pressure and pressure roll position (Pic. 1), with paper weight range 15-20 g/m²; operating speed 1,630-2,000 m/min; operating
The HybriFlex dual-layer solution pack
tisQ.R – low loss factor tan delta standard polyurethane
optimised tisQ.R polyurethane
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the highly wear-resistant top layer allow
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cover (Graph 1). This material property enables use without energy-intensive operation ofperformance. a cooling system for internal cooling of the roll covers. The special metal bonding system provides excellent reliability for the bonding of the roll cover to the core. An application-specific multi-layer structure ensures the transfer of loads under high dynamic stress. Outstanding wear properties and high hardness stability deliver long CMD profile improvements through adaptability running time intervals and stable operating conditions. of the roll cover
Temperatur [ C ] Y
■■ Graph 1. Loss factor tan delta.
Initial practical experience Yankee with tisQ.R on the PM 7
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On initial operation in January Nipload 2018, the roll was not operated with cooling, which reduced the weight of the roll Hardness 20 - 30 P&J in operation by one ton. Start-up of the machine was successful with the Excellent elasticity and low heat build-up following parameters: paper weight 18 g/m²; start-up speed 1,500 m/min, Operation without internal cooling Nipload as a result of new felt installation; no vibrations. After reaching the full Excellent wear properties and high hardness uniformity dewatering performance of the felt, machine speedroll could increased to Pressure with be single-layer cover 2,000 m/min on production of even Surface designs: blind holes, grooving ■■ Pressure roll tisQ.R. 16 g/m² tissue paper over a long time. The vibration level was very low during the entire running time and had no width 2.710 mm. In the past, WEPA experienced unacceptable negative impact on product quality and machine efficiency. limits at the pressure roll position due to an increase in The roll was replaced in accordance with plan in vibrations which had a negative impact on product quality and November 2018 after a running time of 10 months. Based which reduced the running time intervals. Since the cooling on data from the grinding records, the material already system of the pressure roll is not fitted with a syphon system, confirms its excellent wear properties, i.e. very low wear: water content of the roll could not be regulated. Customer delivery diameter 957 mm; diameter after grinding 956 mm. suspected a negative impact because operation conditions Uwe Bigge, Technical Manager at WEPA Marsberg-Giershagen, could not be exactly defined. To optimise performance at confirms the success of initial application: “After 10 months this position, SchäferRolls GmbH & Co. KG was requested running time, we have removed the pressure roll as planned. to meet the following requirements relating to a roll cover: The roll recorded no problems during the entire running time“. ● roll cover must be operable without cooling in order to ensure Y HybriFlex for pressure rolls definable operating conditions; targeted running time Hardness 20 – 35 P&J 1 year; Vmax 2,000 m/min. Graph 2. Properties tisQ.R for pressure rolls
SCHÄFERROLLS GMBH & CO. KG
Solution proposed by SchäferRolls The tisQ.R material optimized for application in pressure roll positions has a very low loss factor tan delta, an indication of its excellent elasticity and the low heat build-up inside the
HybriFlex technology – separation of fun
Benzstrasse 40 71272 Renningen - Germany ■ website: www.schaeferrolls.com ■ phone: +49 7159 8060 ■ email: email@example.com
High elasticity for remarkable adaptability Outstanding wear properties Surface designs: blind holes, grooving
Ecova Paper Wrap from Little Rapids Corporation on the Infinity Eclipse T4 Multi-pack Wrapper Over the past six months Infinity has partnered with Little Rapids Corporation to develop market changing designs in a paper overwrap material called Ecova. by: Infinity Machine & Engineering Corp.
dvantages of the Ecova paper overwrap material versus other solutions on the market start with the fact that Ecova is truly 100% plastic free. Also, the Ecova paper overwrap material is made with 100% recycled fiber. There is not a thin layer of plastic applied to the paper overwrap material to make it seal inside the wrapper which defeats the purpose of the being eco-friendly. Instead, with Ecova, a glue is applied to the
paper overwrap material during the production process of the paper reel. When the production process is complete, the Ecova paper overwrap reel can be used on a wrapper just like a poly reel. During the initial tests, the Ecova paper overwrap material has been tested and verified using an Infinity Eclipse T4 multi-pack wrapper. The Infinity Eclipse T4 multi-pack wrapper operates using four lanes of infeed from an infeed conveyor (five lanes optional) and then separates the product via a servo choke belt
▲▲Bottom seal on finished package from Infinity Eclipse T4. tFinished t package using Ecova paper overwrap on Infinity Eclipse T4 wrapper.
▼▼Collated finished packs using Ecova paper overwrap inside Infinity casepacker.
sealer and side sealing belts then re-heat the glue to seal the pack, and the perfect paper wrapped pack is created. The glue which was applied before entering the machine means that there is no additional external glue system needed on Infinity’s wrapper and no contamination to the machine from an external glue system. Infinity and Little Rapids Corporation have run the Ecova paper overwrap material in production on two formats including two-pack household towel and four-pack bath tissue. Each of these formats ran without making any machine modifications to Infinity’s Eclipse T4 multi-pack wrapper. The Infinity Eclipse T4 multi-pack wrapper was able to achieve speeds of 100 PPM. On these production lines, this was the max output from the winder. In addition, the packs were run through an Infinity conveyor system, Infinity casepacker, and Infinity case sealer to create the ultimate eco-friendly line with no plastic used at all! The Infinity case packer and case sealer are an industry standard when it comes to tissue packaging. Infinity case packers are designed to automatically erect a case or tray, collate the incoming product, fill the case or tray, and discharge it onto a live roller conveyor to the case sealer. The Infinity Eclipse T4 multi-pack wrapper, casepacker and case sealer, along with the Little Rapids Ecova paper overwrap solution is all engineered to perform and provide an eco-friendly option for the future. Whether the future of tissue packaging is paper wrap, bio-plastic, cartons, cases, bundles or standard poly, Infinity along with their various industry partners, like Little Rapids Corporation, have all the tissue packaging technology to help put the companies in a market leading position. ●
Only Infinity: the perfect integration of packaging machinery and engineering services infeed into the flight bar stacking section. The machine then synchronizes each layer into a secondary flight bar system for loading onto the elevator and then into the overhead system. The overhead section operates using a brush style head folder system, which creates continuous forward motion on the paper wrap as the ends of the pack are folded. This forward motion helps to achieving high speeds with the paper wrap because the brush system does not pull back on the paper as it is folded which can also cause jams. In addition, this forward motion creates a higher quality finished package. The overhead unit also features 24 overhead trolleys which reduces the amount of time required for changeovers versus competitors. The Eclipse T4 unwind system is located directly opposite of the roll infeed and is designed to consistently and accurately place a sheet of paper overwrap material around the tissue rolls in order to ensure a high-quality finished package. As the collated pack moves through the overhead, the wrapper’s bottom
▼▼Ecova paper overwrap reel on Infinity Eclipse T4 wrapper unwind.
INFINITY MACHINE & ENGINEERING CORP. 2249 American Blvd. De Pere WI 54115 - USA ■ contact person: Ryan Holmer, Technical Sales/Marketing Manager ■ email: firstname.lastname@example.org - email@example.com
POWER-JET CLEANER TM
Engineered fabric cleaning solutions • DRY-END and WET-END applications • Dislodging contaminants from the fabric
• Same technology for wet and dry parts • Greater cleaning efficiency • Less use of water
• Removal of contaminants from the machine • Absence of vacuum (even in the dryer)
Paprima Industries is a prominent Canadian company. It is the world leader with state-of-theart offerings of High Pressure Water-Jet Technology mainly for the Pulp and Paper Industry with over 30 years of experience.
• Absence of misting
• Modular shift in CD More than 700 installations worldwide
CONTACT OUR REPRESENTATIVES TODAY!
514.422.9555 • firstname.lastname@example.org • paprima.ca 75 Guthrie, Dorval (Montreal), Quebec CANADA H9P 2P1
Innovative Tissue Winding Technology
Tecno Paper is focused on winding systems technology and its core business is supplying brand new and rebuilding of winders for Tissue, Kraft, Fine papers and others. The competitive advantage of the company is the flexibility and optimization of its products and solutions. by: Mauro Della Santa, Sales Director Tecno Paper Srl
▲▲TP-SOFT TOUCH Unwinder. General view of “Double Reel” arrangement. The Unwinder can be supplied also in “Single Reel” version and as a stand-alone unit.
n recent years, the tissue market has requested products with different characteristics than in the past. Softness, high bulk, lower weights have become elements of absolute importance for the most recent types of tissue. At the same time, operators in the sector have requested machines, both in production and in converting, of ever-increasing capacity, and also the production sites have reached significant levels of efficiency. All this to optimize production costs even with types of tissues more difficult to produce and manage in all stages of the process than in the past. One of the phases of the process is the rewinding - slitting - combining which is between production and converting. So even the machines dedicated to these operations need to evolve technologically and from the point of view of performance to meet the new needs and demands of the market. Tecno Paper has always been attentive to changes in the products on the market and to the consequent new needs of tissue producers; this is because the core business of the company is the winding technology of tissue and other types of paper in all its aspects. The study of the technical team in Tecno Paper has
been therefore mainly directed to find process solutions avoiding deformation of the reels, but at the same time allowing an operator friendly use of the rewinding line and an increase of productivity. More than ten years ago, Tecno Paper had already developed and installed in several paper mills a type of unwinder, named MultiFunction, with double unwind system: peripheral with belts and centre drive with direct connection of the reel spool to the driving motor. This type of unwinder
be enough. This is why the R&D team of Tecno Paper has developed a new family of rewinding line denominated TP-Soft Touch, which starts with an innovative unwinder and then continues with an important improvement of the rewinding head. The TP-Soft Touch Unwinder is ﬁtted with innovative and dedicated drive and control systems for low density tissue reels, thus allowing to reach, and ensuring, high precision, accuracy and productivity for the
TP-Soft Touch, the innovative winding concept of Tecno Paper for Super Soft Tissue helped to solve many problems and to increase performances, thanks to the possibility to use both systems together or separately. It is also fitted with a very accurate web tension control system with load cells. But, nowadays on the Tissue market there are present products whose reels coming from the Tissue Machines have a very low density, thus making them difficult to handle in rewinding lines, and also the performances offered by the MultiFunction Unwinder might not
unwind process on rewinding lines. The features of the TP-Soft Touch Unwinder allows to reach the following performances: less specific pressure to have the needed rotation movement, thanks to extended nip on carrying drums; no “torsion” effect in the structure of the reel, thanks to centre drive assist; increased operation efficiency, thanks to fast reel change; high precision and constant NIP control, thanks to load cells measurement of NIP and reel weight; even unwinding
patented, a rewinding method, named “TP-StopLess” able to increase the operation efficiency significantly. For the productivity “speed is not all”, but efficiency has a great impact. This method allows to perform the finished reel change without stopping the rewinder, but only reducing the speed.
Main features and beneﬁts offered by TP-StopLess system Efficiency increase of the winder by
litter-Winders (tissue, paper, board, special papers), Rewinders (salvage, special applications), Reelers (hydraulic, pneumatic, NIP controlled winding), Re-reelers, Unwinders (conventional, tension control, shaftless), Calenders (crown control, skew), Paper Machines sections (presses, cylinders, rolls, shafts, fourdriniers), Spare Parts, Slitter-Winders revamping, Paper Machines revamping, Technical Surveys, Engineering, Maintenance services.
operation, thanks to high precision vertical movement of reel spool carriages. The TP-Soft Touch Unwinder doesn’t give any deformation to the tissue reels and it can be installed in existing Rewinding Lines and Converting Lines as well. Parallel to the technological and performance development of the unwinding section, Tecno Paper has also dedicated itself to the winding part and has developed a closed loop electro-hydraulic system that guarantees high precision in the relieving action of the chucks and the rider roller. The uniformity of the relieving action, its precision and the correspondence to the desired values of the NIP of the reel on the carrying drums and the NIP of the rider on the reel, are guaranteed by the system
feedback based on the signals received by the load cells mounted on the chucks and rider roll. When processing Super Soft tissue reels another issue arises: at high speed the reel stability on the carrying drums is significantly reduced, due to the high relieving action, with consequent reduction of the NIP on the carrying drums, requested not to give permanent deformation to the structure of the product. This situation leads to an inevitable reduction in operating speed, which has the consequent negative impact on productivity. In order to keep high the productivity of Tissue winders, enabling them to match the output of tissue machines, also in those cases where speed cannot be raised, Tecno Paper has developed, and
15% to 22%, depending on several factors like number of unwind stands in operation, diameter of parent reels, diameter of finished reels; Very smooth finished reel removal obtained by a dedicated device which gently pulls the reel off the carrying drums and positions it onto the lowering cradle, thus avoiding any deformation to the reel structure. This device has replaced the traditional hydraulic pusher; High precision “Closed Loop” NIP control of reels against all rolls during the entire winding operation (reel growth and finished reel change); No free movement of reels at any phase of winding operation; Bulk and crepe loss reduced at the minimum extent; Control system and HMI are very operator friendly; Integration with TP-Win 4.0 e TP-Service. Tecno Paper is also very active in Service for rebuilding, refurbishment, modernization, technological improvement, safety implementation and certification of existing winding machines; further to normal maintenance and repair works in paper mills. ●
TECNO PAPER SRL Via S. Martino 36 Fraz. Marlia 55012 Capannori (LU) - Italy ■ website: www.tecnopaperitalia.it ■ phone: +39 0583 299023 ■ email: email@example.com ■ contact person: Mauro Della Santa
Solar Turbines: A NEW CONCEPT OF SERVICE
uuIntegrated Energy Solutions.
n the industrial production of sectors with high energy consumption, such as the paper industry, energy management is relevant and technology essential. With a machinery fleet of more than 16,000 units and 1,200 gas turbine-powered industrial cogeneration plants worldwide, 350 of which in the pulp and paper sector (20 with direct drying for the tissue sector), Solar Turbines, a subsidiary of Caterpillar, confirms its leadership in the production of 3.5 to 23 MW gas turbines. But that is not all the team can provide. Today management services make a real difference in plant efficiency. Solar Turbines partners with its customers operating in various fields on an international scale to analyse possible evolutions of their value chain and create solutions that consider individual needs.
In an increasingly sustainable economy, the manufacturing sector must be able to keep its energy management in step with this trend. Smart grids, use of biofuels and energy transition require the tissue paper mills to investigate technological solutions from an IIoT (Industrial Internet of Things) perspective. This means a complete redesign of the interaction with the by: Solar Turbines Switzerland Sagl “maintenance services”. Value Co-Generation and a new service
Evolving toward a Smart Grid
“We are experiencing a period of extraordinary innovation”, says Paolo Masiero, head of the Solar Turbines Market Development team. “In recent years, there has been an exponential growth in technological solutions supported by digitisation and IT in all sectors. As a result, we have decided to launch an internal program called Value Co-Generation.” Borrowing from the term “co-creation,” which implies a close collaboration between supplier and corporate customer, the program focuses on developing further technological solutions and offering consulting services. “What we
In this context, various departments of Solar Turbines have come into play, each of which follow customers from project definition to plant start-up, with a level of assistance that reaches beyond traditional services and makes use of digitisation. “Through the Insight digital platform, built into the workflow of the Solar Digital business unit that deals with energy optimisation - explains Masiero - we can continually check with the customer and in real time, the production performance of the gas turbine installed. The platform can be linked to the production
Powering the future through innovative energy solutions have done is change the perspective”, explains Masiero. The result is a new and more elaborate concept of service. Underpinning the programme is the rationale of working in partnership with machinery suppliers, in order to identify plant specifications or modifications functional to the results that the customer wishes to achieve. The turbine goes from a standard solution to a fully integrated component of the specific installation.
Solar Turbines delivers high value, products and services to customers ERP system and, in some cases, will balance automatically based on the cost of the energy on the grid.” Insight takes account of endogenous and exogenous parameters of the production line, balancing automatically based on the energy demands of the plant, on the one hand, and of the grid, on the other. This IIoT (Industrial Internet of Things) application places the production site within a smart grid. “It is a new concept of service that goes beyond the technologies installed and makes us look at our offering in an innovative way.”
▲▲Smart Gas Turbines: utilities generators and connectivity enablers.
SOLAR TURBINES SWITZERLAND SAGL Via Campagna 15 6595 Riazzino - Switzerland ■ website: www.solarturbines.com ■ phone: + 41 91 8511511 ■ contact person: Paolo Masiero, Manager Market Development ■ email: firstname.lastname@example.org
Gas: an ideal bridge toward the sustainable economy The goal is to provide companies with the tools to achieve their sustainability requirements, first and foremost through decarbonisation. This means having sustainable production processes and limiting CO2 emissions. In addition to the patented SoLoNOx combustion system, which minimises the production of NOX, the real step forward has been the development of innovative combustion systems which allows us to be ready today for the fuels of tomorrow. Masiero explains: “Our latest-generation Titan 130, Taurus 60 and T70 turbines, ideal for application in the tissue applications, can burn green fuels: biogas and syngas, both up to 100%, and hydrogen blends of up to 70% and more”. Of fundamental importance is the improvement in the efficiency of the cogeneration gas turbines, which today exceeds 85%, making it possible to obtain substantial reductions in the CO2/MWel produced. “Gas can thus ferry us towards a totally sustainable economy, with gas turbines proving an excellent means of guiding us towards a highly sustainable future”, adds Masiero. Creating value and sustainability through the careful management of self-generated energy is, therefore, possible. Solar Turbines makes this concretely possible in the tissue sector by combining innovative IIoT technologies with a service system that looks beyond mere maintenance. ●
Papermaking. Next Level As a strong partner, Voith helps improve the market success of its customers and is already paving the way to the future today. From products and components through plant engineering and digitization to perfectly tailored service packages, Voith offers the ideal solutions for raising profitability and efficiency to the next level. Thatâ&#x20AC;&#x2122;s Papermaking. Next Level
Ecological agility to Innovation ability Over the years, the packaging industry has gone through important changes, especially in the last decade where we are seeing a real evolution. The entire production process has been affected by the green revolution and a full awareness for environment respect is really a relevant must. by: Amotek Sales & Service Srl
Eco-friendly packaging conversion is possible both on Amotek baggers and on complete Amotek packaging systems. This flexibility grants a big advantage for the final customer that can execute a multitude of green materials to replace PE partially or totally at its discretion, without applying any consistent modification on the existing equipment. Beyond bioplastics and compostable materials, Amotek is developing in partnership with leading bag makers, the most suitable type of paper bag to pack tissue disposable products obtaining positive results. Amotek also focused its research and development on consistent material savings in bag thickness to offer its partners eco-friendly materials together with a reduction of packing material up to 30 percent compared to the standard of use worldwide.
Technology improvements are always appreciated among final users. Amotek found the right way to invest its resources in this sense to develop high-class components and user-friendly tools. The aim is to give benefits to Amotek partners, increasing value, efficiency and granting a good quality to price ratio. This company vision positions Amotek not as a common brand only, but rather an ethical company oriented to preserve environmental quality and improve the productivity and efficiency of its customers, always supporting them with excellent tools. Amotekâ&#x20AC;&#x2122;s new sustainable machine generation
Fully-automated solutions for packaging of soft hygienic disposable products and consumer goods
■■ Amotek Tissue Rolls machines.
offers several innovative points based on Industry 4.0. In particular, relevant improvements in terms of data collection and monitoring have been achieved and are now successfully adopted on all Amotek baggers. The simplified usability has been reached with a new, smart and interactive HMI for a proactive and easier maintenance and assistance. A dedicated page displays the machine’s production data in realtime showing the production performance. Upon demand, instead of the standard mirror’s system, the state of the machine is continuously recorded through a video camera system to promptly react in the production process, improving quality by allowing the operator to watch in slow motion what is happening inside the machine. Two camera points are defined by default, while the third positioning is defined according to the customer’s needs. The improved user guidance allows users to have the necessary documentation related
et in touch with Amotek’s new LinkedIn page to be constantly updated on what is going on with Amotek (www.linkedin.com/company/amotek). The next unmissable tissue appointments to meet Amotek and to know more about technical developments are: • Tissue World Istanbul, from September 15-17, 2020 Istanbul (Turkey). Amotek booth no. C115. • MIAC show, from October 14-16, 2020 in Lucca (Italy). Amotek will be at booth no. 121.
▼▼Various type materials execution on Amotek baggers.
to the machines on-board. It can display a variety of content including the digital and interactive spare parts catalogue to facilitate the identification of the component to be replaced without any doubt. 3D video tutorials for size changeover and maintenance activities are based on images instead of written instructions
During the whole lifetime of our machines, we listen to our customers and do our best to satisfy their needs
to avoid wrong technical interpretation given from not native-speaker translations. For many years, Amotek has adopted a controlled data connection to reach a high confidential level of its remote assistance according to the Internet of Things (IOT) era. Every connection is released through a specific protected server where access is only allowed from the customer and from Amotek technician only for the necessary time of the tele assistance with a dedicated password. It is an efficient and incisive method in compliance with standard cyber security and is constantly updated. To grant access for remote assistance, it is no longer necessary to have the bagger always connected to the internet, but upon a specific customer demand, the connection is temporary and, in respect of the company privacy, other company data cannot be accessed. Last but not least, Amotek offers a new generation of smart baggers with a renewed charming style and sturdier frame. As known, Amotek baggers are especially flexible, scalable, and customizable to adapt to different plant installations. Amotek provides very professional after sales service for all customers, no matter their level of experience. It is managed with care by a dedicated and experienced team of skilled personnel, with the goal to support customers from installation to the production phase. ●
AMOTEK SALES & SERVICE SRL Via Piemonte 5 40069 Zola Predosa (BO) - Italy ■ website: www.amotek.com ■ phone: +39 051 6186811
■■ User-friendly Amotek bagger.
■ email: email@example.com
OCME and Robopac:
advanced solutions for monitoring tissue plants
uuGenesis stretch wrapping machine with rotating ring equipped with Cube Technology.
A great project for the most important Tissue company in South America: OCME and Robopac, in fact, have been chosen by an important South American multinational company active for years in the production of toilet paper and paper for domestic use. by: OCME Srl
giant in the packaging sector, which has therefore relied on the end-of-line solutions proposed by Robopac OCME, modular and flexible systems, which meet the needs of customers. A special customer, to whom Robopac and OCME have supplied a new end-of-line installation with various robotic palletizers, wrapping machines and laser-guided vehicles with battery and automatic transmission. The installation allows to palletize and wrap overlapping pallets of packaging and cartons containing rolls of toilet paper and kitchen paper. OCME has developed a system able to achieve four objectives: palletizing flexibility and high speed, product care, traceability of materials and monitoring of the efficiency of the lines. The packaging takes place thanks to Robopacâ&#x20AC;&#x2122;s Genesis Cube, a wrapping machine with rotating ring that provides a stable pallet using reduced quantities of film. The pallets are individually packed and a full column of them is made up of two overlapping pallets: the machine wraps the lower pallet and then, once the cycle is finished and the film is cut, it shifts to the upper pallet and starts a new wrapping cycle. Once the packaging is finished, both overlapping pallets are individually labeled to ensure the traceability of the line. A destacker submits the individual pallets under a device that controls the quality of the pallet. In the event that the pallets pass the test, they are re-stacked in a second stacker and
â&#x2013; â&#x2013; A dashboard example of the Remote Control & Monitoring system.
Our solutions: a full range of technology and innovation 91
■■ Auriga 15CT laser guided vehicle.
■■ Pegasus robot palletiser with complete layer gripper.
OCME proposes integrated automation systems for the end-of-line that manage tissue products with optimal care removed from the LGV. Traceability will be guaranteed thanks to the continuous exchange of signals between the LGV system (OCME pallet transport vehicles) and the loading and unloading stations. A great advantage of LGV, besides avoiding the installation of tracks, is the possibility of automatically transporting pallets of raw materials to the production lines. Among the solutions offered by Robopac OCME, there is also a cutting-edge monitoring and analysis tool. This service allows, with a remote connection and high security protocols, to monitor and control through personalized dashboards the performance and efficiency of machines and lines, faults and analysis of stops and customized reports. This communication is possible thanks to an intelligent supervision system, fully customizable according to the characteristics of the line and customer requests, which
can monitor both OCME machines and different systems by using the most common communication protocols to provide a complete overview of the line of production. In this way it is possible to control the work of all the machines on all the production lines through an intuitive and interactive user interface, usable both remotely (headquarters or other group offices) and in the production areas. For example, the customer was able to check the real-time operation of all its plants worldwide through the Robopac-OCME Control Center. The diagnostic dashboard allows you to see the 3D layout of the machine and its equipment and identify the area where there could be a possible error. The analysis of alerts allows you to estimate the impact of each failure on production: this allows customers to find the right solution to the problem. Sharing and connection are the keywords of this high-tech experience that makes Robopac costumers’ business grow, in real time and everywhere. ●
OCME SRL Via del Popolo 20/a 43122 Parma - Italy ■ website: www.ocme.com ■ phone: +39 0521 275111 ■ email: firstname.lastname@example.org ■ contact person: Marcello Lusardi, Tissue Sales Manager ■ email: email@example.com
■■ Web inspection provides real-time analysis across the full width of the wire to record and classify defects.
igh-resolution cameras and comprehensive event capturing and quality inspection software not only deliver full process visibility, they also provide the opportunity to address issues at their root source, allowing overall machine efficiency (OEE) to be maximized without jeopardizing operator safety.
DISCUSSION Full visibility into all production processes is fundamental to the overall success of any tissue operation and yet most operators are not able to answer a resounding “yes” to the following questions. Can tissue machine, converting line, packaging line and palletizer processes be safely observed?
Is there a means on every machine to visually capture an unwanted process event and to find its root cause? Is there a means of viewing uninterrupted video footage from the past 24 hours (or more) of process? Is there a means of identifying and eliminating poor quality product at the end of each process stage? These questions can be answered with a “yes” if a high speed and high-resolution camera-based event capturing and quality inspection system has been fully integrated into the process of operating each machine or line. Simple visibility can be provided by any surveillance system; however, full synchronized process visibility, with automatic event and quality analysis can only be achieved through advanced event capturing, web inspection and discreet item inspection systems, such
as Papertech’s set of TotalVisionTM solutions. The motivators that warrant an investment in such solutions are:
The need for efficient high-quality production Excessive process interruptions Is the tissue machine operation interrupted by frequent web breaks? Would solving the root cause of the breaks improve the plants return on assets? Web break footage can be acquired by an event capturing system through strategically located cameras each synchronized to see the same web area to ensure rapid root cause analysis. Product quality problems Are converting operations inefficient as a result of an unacceptable number of product defects in finished reels? An advanced event capturing system with web inspection capabilities
Effectively solving tissue production, converting and packaging problems
using event capturing camera systems Increasing demands for operator safety, faster production speeds and enhanced product quality make it imperative to have visibility of all production processes. by: Martin Rempel - Papertech Inc. - Hamburg, Germany
can map and classify defects. Together with additional critically located cameras, the system can often show the defects’ root causes.
Eliminating converting bottlenecks Operate with knowledge of incoming product quality Could knowledge of the quality of incoming product improve converting line setup and reduce process interruptions due to web defects? Could product quality be improved by running reels of lesser quality as middle plies on a multi-ply re-winder? OEE increases can be achieved via the automatic receipt of accurate reel quality maps (provided by a web inspection system on the tissue machine) at the converting line. Excessive process interruptions Could process engineers, who are
presented with the increased challenges of complex converting sequences, solve converting issues quicker with visual information? A typical re-winder may experience process interruptions due to faulty transfers, improper web tensioning, poor web quality, incorrect embosser setup, laminating problems, incomplete perforations, log formation issues, vibrations and log bounce and improper core insertion. An event capturing system is the only solution for capturing these events for slow motion playback and root-cause analysis. Ensuring a high-quality end product Can assurance be provided that end product meets the customer’s minimum requirements? Without knowledge of incoming product quality and the ability
▲▲High resolution camera.
to measure quality parameters, the end product is often packaged in the “good faith” that it meets customer quality requirements. However, top tier converters have started rejecting product based on base sheet flaws and monitoring other quality factors using camera-based quality inspection systems.
Eliminating packaging and palletizing problems Excessive process interruptions As on a converting line, could process engineers solve packaging issues quicker with visual information? Packaging lines and are enclosed, high-speed processes and an event capturing system provides the only alternative to capture and present issues that occur in the packaging sequence. Ensuring a high-quality end product Can assurance be provided that the package and placement of the
Papertech is the Vision technology vendor of choice for industry leaders in Paper Production in the World product inside of the package meet the customer’s minimum requirements? Inline camera-based quality inspection systems are able to see and alarm on package flaws as well as when product is incorrectly positioned inside of clear wrappers. These are just a few examples of how event-capturing and quality inspection systems can meet the needs of tissue producers and converters.
RESULTS An event-capturing and quality inspection solution investment will typically provide the quickest payback and provide the largest return on investment under the following scenarios. 1. Rapid and efficient start-up of a new tissue machine, converting, or packaging line Visibility and proof of commissioning problems will ensure that a new machine or line is up and running as fast as possible. The return-on-investment is achieved by being able to rapidly find out where process interruptions are occurring and why, as well as finding the sources of quality issues that prevent new lines from achieving desired production output on schedule. 2. Improving the performance of an existing machine Rebuilding or re-purposing an existing machine for a change in product output and quality poses similar challenges as commissioning a new machine. Also, any machine that is
ttPapertech’s WebVision software and cameras can monitor a preset region of interest on the paper web and alarm for any change in the sheet.
production-limited can often benefit from an event capturing solution that provides the ability to resolve unwanted process interruptions. 3. Eliminating poor quality Product claims can be costly. The ability to measure and document the quality in each production phase-production, converting and packaging can shorten extensive quality investigations. Also, the ability to eliminate poor quality product at its production source can provide a very large payback to any organization with quality concerns. 4. Conforming to new safety and operator training regulations-machine guarding Many operators are faced with decreased or often completely restricted visibility of their machines as a result of newly implemented safety guarding measures. An event-capturing solution can restore operator-machine visibility, and also enhance it to levels otherwise unattainable.
CONCLUSION High speed camera technology for both event-capturing and quality inspection has a clear return on investment for tissue machines and converting and packaging lines. Proof of this is the rapid growth in vision-based system installations by first and second tier tissue producers who see it as paramount that their assets deliver the best possible OEE. ●
PAPERTECH INC., HEAD OFFICE 219 East 1st Street North Vancouver, B.C. V7L 1B4 - Canada ■ website: www.papertech.ca - www.ibs-ppg.com ■ phone: +1 604 914 2097 ■ contact person: Ken Barbour, Marketing & Communications Manager
AZMEC A 60 YEARS JOURNEY
ADV Elisa Ghiotto - Ph. @ superrox - Località Campo Imperatore (AQ)
• DESIGN AND MANUFACTURE OF LIQUID RING VACUUM PUMPS • MAINTENANCE OF PUMPS AND MECHANICAL PLANTS • AT YOUR SERVICE SINCE 1960 • 100% MADE IN ITALY
â&#x2013;˛â&#x2013;˛SENNING production hall no. 1.
ENNING machines provide tailor-made solutions and are developed and built according to special customer requirements, like unusual formats, special sizes, special closure options and new eco-friendly packaging. SENNING wrapping machines for more sustainability and environmental friendliness in the packaging of tissue and paper products. In order to support the eco-friendly production of tissue-packaging, SENNING has developed
Reliable and innovative solutions for the wrapping of paper and tissue products 98
a new option for full paper wrapping for its packaging machines in order to help reducing plastic waste. Several kinds of paper have been tested and found suitable for being processed on SENNING machines. Napkins, e.g., remain visible when wrapped in almost transparent kraft paper or glassine. All tested papers are 100% recyclable and compostable. SENNING does not recommend to work with fully coated papers because some of these coatings can make composting and recycling of the papers impossible. Even SENNING packaging machines already in operation can be retrofitted for paper wrapping. SENNING machines can also be used to wrap tissue products in recyclable and/or compostable environmental-friendly film, made of renewable raw materials. Development and construction of SENNING machines completely Made in Germany. SENNING machines are extremely
first-class machines for first-class products Christian SENNING Verpackungsmaschinen is the specialist in the field of packaging machines for tissue and paper products. by: Christian Senning Verpackungsmaschinen GmbH & Co. KG robust, durable and reliable in production. All components and production parts are manufactured by renowned German suppliers. These high-quality components together with the excellent know-how of SENNING engineers result in the high quality of SENNING machines and of the goods produced by SENNING machines. Moreover, the electrical programming of each SENNING machine is done individually by SENNING engineers. The high-end quality of SENNING machines results in less
downtimes and thus, in higher profitability. Maximization by modernization. Even the best packaging machine can only deliver top performance in the long run if it is well maintained and upgraded at regular intervals. SENNING Services offer a comprehensive modernization service according to the latest state-of-the-art: for improved performance and high output of SENNING machines. SENNINGâ&#x20AC;&#x2122;s modernization services range from classic technical upgrades to complete machine
hristian SENNING Verpackungsmaschinen, Bremen, Germany, is one of the leading suppliers of high-end wrapping machines for tissue and paper products, with more than 70 years of experience on the world market. Products: complete handkerchief lines incl. folder, wrapping machines for napkins, facial tissues, handkerchiefs, handtowels, non-woven products and individual wrapping machines with tailor-made solutions for customers’ specific needs and requirements.
Some available upgrades for SENNING machines For SENNING handkerchief single pack
▲▲Napkin packages in kraft paper and glassine, wrapped by SENNING machines.
▼▼New type of sensor at SENNING single pack wrapping machines.
conversions. They are always in line with the latest safety guidelines and use the most innovative technologies. SENNING offers special electrical upgrades of existing handkerchief lines to PACDrive3 from Schneider which saves space and energy and improves and simplifies the production process. SENNING’s holistic approach extends the life of the equipment and helps to maximize the rentability and profitability of the machines. Benefits for SENNING customers. Upgrades for improved performance; current technologies and safety functions; holistic redevelopment concepts; machine conversions, overhauls and relocations; reconfiguration and recommissioning of systems.
wrapper 525 A and 525 D. A new type of sensor optimizes the package control on SENNING’s single pack wrapping machines for handkerchiefs. The stack is slowed down in front of the sensor and rests against the carrier. In this way, it is possible to check over the entire stack length to see whether tissues protrude or whether the stack is perfect. This exact testing technique minimizes faulty interferences and perfects the stack quality. Autosplicer for SENNING Handkerchief Lines. SENNING handkerchief lines can be equipped or upgraded with auto-splicers. Auto-splicers are available for the folding machine, the single pack wrapping machine, the taper and the bundling machine. All auto-splicers, except the tissue splicer, operate at full speed. The machine operators can flexibly prepare the respective roll change when there is time. The production reliability is increased and thus, the efficiency of the line. Movable cutting station for the SENNING taper. A movable cutting station has been developed for the SENNING tapers SGT 1.1 and 2.1. This enables individual tape placement, adjustment in case of a positional deviation or improved positioning in longitudinal direction. Faster format changeover with the SENNING SE 660 wrapping machine. The SE 660 has been equipped with a quick release for faster format changes to make production more efficient and much more flexible. ●
CHRISTIAN SENNING VERPACKUNGSMASCHINEN GMBH & CO. KG Kalmsweg 10 28239 Bremen - Germany ■ website: www.senning.de ■ phone: +49 421 694620 ■ email: firstname.lastname@example.org
■■ Biological plant and Deltafloat Paper Mill - Tuscany.
and the environment: water, a precious asset to be treated with care Treat and recover water, fibers, primary and final waters, optimize resources, protect the environment and maintain competitiveness. These are the specialties of O.M.C. Collareda, a Vicenza-based company that uses by: TissueMAG strictly Italian technologies.
e know water wellâ&#x20AC;? is how Bruno Collareda, founder of O.M.C. Collareda based in Schio, province of Vicenza, introduces himself. The treatment and recovery of water and fibers, as well as primary and final water treatment, are at the core of O.M.C. Collareda activities for the paper industry. A sector that tackles, with technologies entirely made in Italy and with a consulting and engineering approach, the needs of paper mills around the world.
An activity in continuous evolution: an interview with Bruno Collareda Mr. Bruno, what is O.M.C. Collareda current activity? Currently, the activity consists in design, production, assembly and start-up of systems to treat water coming from industrial and civil processes, biological systems, primary water treatment, sludge dewatering, stock preparation systems for the Paper Industry, for any type of paper and complete
by case, proposing the most suitable customized solutions in compliance with laws and the main customer’s needs: recycling of raw materials, recovery of water and energy saving. From the very first stages of negotiations, expert people intervene. They are not just commercial ones but “pure” technicians, able to understand the clients’ needs and then formulate the most appropriate solutions to propose.
■■ Company management Collareda Bruno, Viviana and Marco.
When it comes to water treatment and recovery, O.M.C. Collareda can satisfy any of its customers’ needs: from the closing of cycles inside the paper mill, applying flotation systems suitable for the recovery of primary water, to the treatment of wastewater using anaerobic and aerobic biological systems, with the recovery and reuse of treated water through filtration, ultrafiltration and reverse osmosis. Mr. Collareda, all this with completely “Made in Italy” technology? deinking plants. Particular attention is paid to all engineering and design services: with a specialized Technical Department, where skillful technicians work constantly to research and develop new projects in order to be up-to-date, and a Research and Development Laboratory that boasts the most modern equipment. A market where 70% of the systems designed and produced by the company are then installed all over the world. What can you tell us about this? This constant development of the company always led to the stipulation of new important contracts in the USA and Centre-South America. For example, we have just completed a plant in Argentina that will allow our customer, a paper mill of a large group, to recover almost 50% of the wastewater. We are also in the process of starting up an impressive complete water purification plant, worth over six million euros, installed at a Mexican customer. Our commercial technicians never stand still: at the moment, we are in the process of negotiating other plants in Mexico and Russia.
One of our greatest satisfactions is to propose our technology all over the world, boasting the “Made in Italy” manufacturing. In fact, everything is built and pre-assembled by our staff at our factory, and every phase is followed with care. Design, study, ideas, intuitions, are part of our baggage, of our culture, and we are proud of it.
We know water. We design and build water purification systems
You have a wide range of products and technologies that many have tried to imitate. What is it that still sets you apart and makes the difference despite all this? The ability to be partner of our customers and not only simple suppliers is what makes the difference. We meet our customer in person, provided by an accurate technical dossier, with detailed plants projects. We evaluate case
What about certifications? O.M.C. Collareda was one of the first companies back in 1995, to obtain UNI EN ISO 9001 Quality Certificate, a certification that places it on the market with prime standards to guarantee the quality and efficiency of production and management processes. All this without forgetting sustainability and environmental protection: water is a precious asset, essential wealth and life source. We therefore try to protect this unique and valuable resource in every way, continuing to invest in the Italian territory but looking also at globalization. ●
O.M.C. COLLAREDA SRL Via Lazio 10 36015 Schio (VI) - Italy ■ website: www.omc-collareda.com ■ phone: +39 0445 575281 ■ email: email@example.com
▲▲Ultrafiltration plant Paper Mill Mexico.
■ contact person: Eng. Stefano Tomiello, Sales Manager
New Microline Fast Wrap:
â&#x2013;˛â&#x2013;˛Fast Wrap 1250: a machine destined to lead the way in terms of performance and flexibility.
With more than twenty years experience in the design, construction and sale of tissue-sector packaging solutions, the company from Bologna is about to launch Fast Wrap 1250, a machine destined to lead the way in by: Microline Srl terms of productivity and flexibility. 106
increasingly higher performance gives Tissue sector a boost When technology meets tradition In a constantly-changing market, it is essential to design machines offering higher, but at the same time flexible, performance capable of adapting to specific production requirements. With this in mind, Microline has developed Fast Wrap 1250, the new continuous-motion bundler for AFH paper rolls. With this multi-pack bundler, the company has set its sights on flexibility and production speed: two essential features for the Tissue industry that finds itself having to pack batches of different-sized products with ever-increasing frequency. Fast Wrap 1250 can process 25 bundles per minute without compromising the quality of the products contained therein and the packaging’s appearance. A feature of version 2.0 of Microline’s existing range of bundlers is the extensive size range available with the possibility of performing most size changeovers directly from the control panel. Wrapping involves placing the film around the prearranged rolls, joining and subsequently sealing the edges at the top of
Microline solutions for the tissue sector guarantee high performance thanks to top quality machines
the bag. Front and rear sealing is performed by a hot bar self-centring system (box-motion cycle) that separates the bundles. The entire packaging process is carried out without producing packaging material waste or trimmings, once again underlining Microline’s corporate philosophy that has always been careful not to waste energy and raw materials. Indeed, the Bologna company has always been committed to cutting energy running costs and the quantity of packaging material utilised compared to its competitors by between 10% and 30%.
▲▲Microline, 20 years of experience.
The importance of the customer partnership Fast Wrap boosts the range of Microline solutions comprising machinery capable of adapting to a wide selection of tissue-packing
▲▲Bag entering the shrinking tunnel.
uuDetail of the sealing station.
and end-of-line requirements. The company once again confirms its status as a hi-tech business, customising its products to suit customer needs and supplying state-of-the-art machinery assembled with the care of a traditional craftsman. Microline’s meticulous design of its conveyor systems is proof of this: each section is designed to improve the performance, productivity and functionality of the entire packaging system. The company’s conveyors are therefore optimised for product type and task performed in order to meet the various requirements of the customer who
Microline has always considered to be just like a partner. Indeed, ever since the day it was founded, the Bologna company has always placed the customer at the centre of the entire system, involving him from the design stage right up until delivery. Microline also provides customers with all the tools needed to train staff, at the same time guaranteeing ongoing support and assistance. Indeed, one of the main selling points of a Microline product is the optional remote assistance: technology developed so that the company can communicate with a customer in need of assistance with just one click. The MRA (Microline Remote Assistance) system is a quick, convenient, time-saving solution that can avoid downtime. A simple Internet connection is all that is needed to communicate with a Microline specialist staff member and take him virtually to the machine’s location in order to provide remote assistance. An effective optional available for all of its packaging machines, enabling the company to take an important step towards Industry 4.0. ●
MICROLINE SRL Via Emilia 33/C 40011 Anzola dell’Emilia (BO) - Italy ■ website: www.microlinesrl.it ■ phone: +39 051 6166696 ■ email: firstname.lastname@example.org ■ contact person: Alessandro Berselli, Sales Manager
PU LP & PAPE R
NEW VE RTICAL CRESCE NT FORME R TISSUE MACHINE Prime LineVRT
Prime LineVRT TISSUE MACHINE FOR IMPROVED DEWATERING OF THE FIBER WEB The PrimeLineVRT tissue machine features a vertical CrescentFormer in the forming section that enhances dewatering of the fiber web. This provides higher dryness right after the press section as well as an increase in paper caliper.
Depending on the grade and basis weight of the paper produced, between two and four percent of additional dryness can be achieved after the press section compared to standard CrescentFormer configurations.
loops or any extra space in the basement for installation of the equipment. This results in lower building costs as well as easier operation and maintenance compared to similar technologies on the market.
The advantage of this new technology is that there is no need for additional fabrics, fabric
For more information, please contact us at: email@example.com
ANDRITZ AG ⁄ Stattegger Strasse 18 ⁄ 8045 Graz ⁄ Austria/andritz.com/primelinevrt
Complete and specific plants
for the paper industry Mingazziniâ&#x20AC;&#x2122;s engineering work has been focused on answering the specific industrial needs of the paper industry applying highly reliable technologies, fully tested in different sectors. by: Mingazzini Srl
â&#x2013;˛â&#x2013;˛Exploded drawing of PB series boilers.
inety years of history, high specialization and top reliability: those are the main features of Mingazzini, a company that was founded in 1929 in Parma and today is an international benchmark in the industrial steam boiler sector. The company provides customized answers inspired by its vocation for plants that are more and more reliable and highly technological, guaranteeing safety, professionalism and excellent service consistent with the “Mingazzini standard”. The company, in fact, has been driven by the Research and Development department for almost a century and is able to provide innovative solutions and to anticipate market demands with plants and production processes that are constantly tested and updated from a technological point of view, ensuring top quality and highest efficiency, minimizing at the same time the NOX and CO2 emission values. Mingazzini has always focused on the production of industrial steam boilers with state-of-the-art design for the most efficient management of heating plants of any size, including remote control and management, as well as operation without continuous supervision for 24/72 hours. Every plant built by Mingazzini is carefully engineered and personalized as a tailored suit, in perfect Italian style. The experience gained directly on the field over the decades and the deep knowledge of the process requirements in the most varied sectors are strategic factors that allow Mingazzini to offer a comprehensive service to customers. This also includes innovative solutions designed to meet specific needs,
▲▲Steam boiler model PB 120 complete with economizer.
maximize the investments and reduce the energy consumption. A fundamental dimension, where a relevant increase in the performance of the latest Mingazzini boilers stands out, is the one regarding the gradual reduction of atmospheric emissions thanks to more innovative combustion systems. Combining new-generation “Low NOX” burners to the large combustion chambers that characterize Mingazzini boilers, it is possible to obtain NOX and CO values able to respect the most restrictive local and international regulations in force for emissions.
Our history and know-how to answer to every new and challenging need of the customers
A specific mention is then deserved by the exclusive energy recovery systems that are specifically studied and produced case by case. Every steam boiler of the PB and PVR series guarantee a 90% standard efficiency. Depending on the number of working hours and the type of fuel used, the company can supply energy recovery systems dedicated to the single generator, to achieve efficiencies up to 97.5%. Finally, even higher results can be obtained with the “ARS - Advanced Recovery System” series that is tailored to the customer to achieve efficiencies up to 99%, pushing to the extreme the condensation of the fumes in order to recover as much latent heat as possible (in addition to the sensible heat). To provide a 360-degree service covering every need of the heating plant, Mingazzini also designs and manufactures atmospheric and
ttDeaerator with capacity of 60 m3.
▼▼Detail of economizer installation.
Mingazzini produces a wide range of steam, superheated water and hot water boilers, as well as heat generators pressurized deaerators with capacity up to 60 m3 and rated pressure up to 10 bar, as well as steam manifolds approved according to PED, blow down vessels, water tanks, feed water softeners and reverse osmosis plants. Quality is one of the essential values of a company whose brand name is a guarantee for the customer. Referring to third-party formal certifications, since 2001 Mingazzini’s Quality System obtained the certificate of conformity to the ISO 9001 Norm on the part of Lloyd’s Register Quality Assurance. Moreover, the company obtained since 2002 a certificate of approval of its Quality System with Guarantee of Total Quality according to Module H1 of PED Directive, now Directive 2014/68/EU (Certificate of assessment of Conformity based on
Full Quality Assurance plus Design Examination according to module H1, as per Attachment III of the Directive 2014/68/EU). The client companies addressed by Mingazzini are facing more and more complex challenges and that’s why they deeply appreciate and look for quality and reliability as fundamental characteristics of the plants they’re
MINGAZZINI SRL Via E. Pini 29/A 43126 Parma - Italy ■ website: www.mingazzini.it ■ phone: +39 0521 1880611 ■ email: firstname.lastname@example.org ■ contact person: Eng. Umberto Orlandini ■ email: email@example.com
investing in. Those are imperative features that must be coupled with the most innovative solutions to guarantee the lowest energy consumption and the highest respect for the environment. From the design and manufacturing point of view, Mingazzini firetube boilers fully answer those requirements. They are engineered, built and tested according to the European Directive 2014/68/EU (PED) and have been designed for both “heavy-duty” uses and maximum energy saving. This joint objective is possible thanks to the most modern technical solutions in terms of engineering together with the most advanced manufacturing systems. According to the company’s approach, in order to ensure quality and reliability, at the design level a steam boiler must feature fundamental technical and production details, well recognizable in all Mingazzini boilers. Uncompromising quality and reliability combined with the most innovative technological solutions are Mingazzini’s distinctive factors. ●
ENFASI - SINERGY… PM machine rebuilding
■■ REEBORN phase mounting.
The rebuilding of the PM machine - nearby Lucca - has been done. The old DCS was replaced, re-wired and refreshed by the SAEL “Reeborn” system in 12 working days. The PM machine was formerly driven by ABB drives and DCS. Over the years it became aged: either hardware or software wise, and some spare parts were no longer available. by: SINERGY
nity is strength. The win-win situation played by the emerging group Enfasi & SINERGY who made this big job in a short time is the fact! The customer assigned the rebuilding of its continuous machine to Enfasi & SINERGY (SINERGY a Joint Venture between SAEL, Elettronica Lucense and SIMI&C) - born to supply OEMs and End Users locally, as well as around the world). The individual skills of the players mentioned above, allowed to hit this ambitious target. The PM Machine, originally made in 2001, was suffering from aging of the parts related to the DRV and DCS by ABB. Thanks to the deep knowledge of Mr. Marco Nieri, Head of Enfasi, who started this system in 2001, was possible to replicate the solution into a more modern concept. The QCS was made by last year by Enfasi as well. The needs of the customer and the practical aspects leaded to the Rokwell DCSs platform choice. The old ABB system was removed and quickly re-wired using the new I/O Rokwell boards. The 13 former drives were updated by the SAEL Reeborn system, equipped with Ethernet TCPIP net.
Complete customization and adaptability with any existing production control system
■■ Electrical cabinet where the REEBORN are mounted.
The Reeborn SAEL is an innovative system, performing based, who allows to re-use most of the original drives components, with a relevant cost saving. As long as the customer management is carefully focused on finding the best ratio solution/cost, their choice on Reeborn for this PM job, was a big success for all of us. The wiring proven team ensured the explant of the old DCS ABB on time: 4 days. Apart of the DCS, some output relay boards were replaced as well. At the end of the 4th day, they started the Drives calibration and the routines/tests of the logics and sequences managed by the new DCS. The 5th of January the Paper mill was ready to produce. From today on, a new generation single CPU manages more than 2,000 signals of the PM machine and a small CPU linked to the main one, is dedicated to the continuous machine
We are focused on Pulp & Paper area; we also operate in several other areas and work quite in all industrial sectors Layout Integrated QCS DCS DRV System Architecture
he system installed is a Compact Logix by Rockwell. The HMI is a Ftview by Rockwell. Thanks to the optimized Pulp & Paper libraries, and a hardware integration Enfasi & SINERGY achieved high performance results. The solution, compared to other ones, met the following customer expectations: architecture flexibility; cost saving on spare parts; optimizations on process adjustments (thanks to an high performing 16 bit I/O device).
Drives, only. This architecture separates the two systems allowing the best flexibility on refs. management. The machine automation is based on the SAEL sectional drive with the remote control by “DCS in DRIVE” system, the top solution for this market segment. The high flexibility and functionality of the system mentioned above, whenever applicable to any other machine, immediately highlights benefits in term of cost savings and time-to-resolution. Actually, in this job, Reeborn allows to save and re-use all the existing hardware components like electro-mechanics in the cabinets, some of the driver sections (capacitors, relays, ABB diods section) ensuring a “new life” to the application itself. The results is getting a new system with high performances and, nevertheless, with spare parts available for many many time. Another win of our turnkey approach, which is technically oriented - mainly - with skilled and prepared players, and efficient in terms of costs. ●
SINERGY ■ email: firstname.lastname@example.org
Is This Your Customer?
It Should Be. QUALITYVISION
Are poor quality and too much waste getting you down? Increase happiness by preventing these product defects from reaching your customers:
• Poorly printed, stamp embossed or embossed logos or brand messaging • Product with undesirable defects such as dirt, holes or smudges • Out of spec embossing or printing
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QualityVision™ identifies branding quality issues.
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SABA AUTOMATION presents its new end-of-line solutions for the tissue and paper market 118
“At SABA AUTOMATION, 2019 has been a positive year, which has allowed us to consolidate our presence in the end-of-line market dedicated to the tissue industry. The year 2020 means other important challenges for us; in fact, thanks to the experience achieved, we will be presenting the new innovative ZEUS systems for automatically palletising products in bags and/or single packs (display)”, says Alessandro Pollini, Sales and Marketing Director. by: SABA AUTOMATION Srl
■■ Complete end-of-line SABA AUTOMATION.
ABA AUTOMATION is the Official System Integrator of KUKA, a German manufacturer of industrial robots, with 25 subsidiaries worldwide and a turnover of over 2.5 billion Euros. The integration of these robots, combined with specially designed pick-up implements, as well as product and pallet handling systems, allows the product to be palletised (toilet paper, kitchen paper, napkins, paper handkerchiefs, interfolded paper towels, etc.) gently and without damage. SABA AUTOMATION’s commitment is to never stop innovating, looking for solutions that can effectively help their customers in their production process. Automating the end-of-line process is an essential factor to increase production output. It not only makes operators work better and with less fatigue but also allows the customers to become more competitive and, last but not least, to offer a well-palletised product that is ready to be shipped. It is certain that one of the qualities that sets SABA AUTOMATION apart from other competitors is flexibility; fundamental in order to always find the right solution, the “tailored suit” for the customer.
We develop and produce automatic systems and robot stations for transporting systems
n June 2020, Open House at SABA AUTOMATION facilities; this will be an opportunity to see the machines at work, right where they are designed and built, and to learn more about the latest innovations in terms of palletising bagged products and displays. The company then will be at MIAC in Lucca, where, in addition to meeting the staff at the stand, it will be possible to visit the company and touch SABA AUTOMATION technology at work.
SABA AUTOMATION innovative end-of-line systems ZEUS ROBOT. This solution guarantees ultimate speed in terms of cycles per minute, which means that it can be used for lines with a very high production output. Particular care has been paid towards design of the pick-up implements both for unpacked and packed tissue products. These special grippers grasp the product without causing any kind of deformation; this drastically improves quality of palletising. Grippers are motorised with the robot’s interpolated axis to ensure adequate handling of such a delicate product as is tissue paper. The size changeover system adopted is much more accurate than the typical pneumatic systems so that the gripper does not damage the product. BD CARTESIAN ROBOT. Compact and particularly efficient, they are the ideal solution for lines handling paper napkins, paper handkerchiefs and interfolded paper towels. Cartesian robots designed to operate in three shifts for 365 days a year, with low
▲▲Robot Palletizer SABA AUTOMATION Zeus.
▼▼Cartesian Robot Palletizer SABA AUTOMATION BD.
maintenance requirements and high efficiency. SABA SOFTWARE. Management software and operator-industrial PC interface have been optimised to make line operation easier still and allow for better control over all end-of-line stages. This software can be interfaced with the latest management systems for data exchange, etc. The SABA AUTOMATION programme for handling different product formats is the same for both ZEUS robots and the BD. Thanks to the combination of robot and software, SABA AUTOMATION robotised palletising systems offer more advantages in terms of cycle time reduction, adaptability to different products and elimination of downtime. Operators no longer have to deal with heavy palletising work and no longer have to perform size changeover operations since a production order can be called up and uploaded in an instant. COMPLETE END-OF-LINE SYSTEMS. To complete our end-of-line range, SABA AUTOMATION offers fully automatic solutions for pallet packaging, such as pallet stretch-film wrapping machines, labelling systems and AGV. ●
SABA AUTOMATION SRL Via della Fisica 23/25 41042 Fiorano Modenese (MO) - Italy ■ website: www.sabasrl.com ■ phone: +39 0536 920907 ■ email: email@example.com ■ contact person: Mr. Alessandro Pollini ■ email: firstname.lastname@example.org
Paprima Industries pushes the boundaries of high-pressure fabric cleaning Water consumption is fast becoming a looming environmental issue that affects not only tissue industry, but the global manufacturing sector who uses water in its processes. The public and the government are pressuring us to do better with the water we are using. Developing a Sustainable Water Management Program is kind of the by: Paprima Industries Inc. new mojo in the industry.
ater is used throughout the process of Papermaking. It starts right at the beginning, with the wash and transportation of the pulp, to dilution, cleaning and cooling of equipment just to name a few. Understanding that we all need to do something about this and have a crucial role to play, Paprima Industries decided to look at what we could offer for the cleaning process on paper machines. Following extensive research and development, the company came up with revolutionary Power-Jet Cleaner.
What makes Paprima different
▲▲In this close-up view of the Power-Jet™ Cleaner head, we can see the tornado effect that is created and the initial lift it generates.
A decade ago, Paprima’s team looked at what was available on the market for high-pressure cleaner options, gathering comments from mills considered as industry leaders. They soon realized that there were huge gaps in the performance of those high-pressure cleaners and that the majority of them failed at one point or another. They started their R&D program to transform the cleaning of fabrics. Everything and each step of the cleaning process were looked at, from the angle of the jet to get the most efficient cleaning method, to the
■■ Paprima Power-Jet™ Cleaner in operation on dry-end fabric.
evacuation of the contaminants. The Power-Jet Cleaner was born. It first starts with a round head. Why design a system with a square head to, afterwards, make a transition to round piping or a flexible hose? Square heads have corners, creating areas where contaminants can accumulate. Next was our curtain of air to control and contain the contaminants. Their curtain is less influenced by the gap between the head and the fabric, as a blade would be, and it creates the initial lift for the contaminants and the evacuation of excessive water. Finally, their ejector, which is incorporated into the cleaning head is actually spinning everything in the evacuation tube, making the unit self-cleaning at the same time. The above technology is used for wet end cleaning of fabric as well as dryer felts. However, for dryer cleaning, Paprima added another innovation. The major problem, which is also very costly with dryer cleaners, is what to do with the air you are evacuating? This takes up most of the space inside the piping and makes it prone to plugging. Their solution: adding cyclones to the process. They evacuate the air directly inside the dryer hood, and are now only left with evacuating water and contaminants through a small flexible hose.
▲▲Paprima Power-Jet™ Cleaner installation for operation on wet-end fabric.
ttThe engineering and design of the Power-Jet™ Cleaner was done for ease of maintenance, containment of the cleaning area and optimal removal of water and contaminants with linear jets.
uuTypically, the Power-Jet™ Cleaner will maintain fabric air permeability at 80% of the as-measured permeability of a new fabric - for the life of the fabric.
World leader in state-of-the-art High Pressure Water Jet Technology for the Pulp and Paper Industry The result A perfect cleaning of the fabric, exceeding papermakers’ expectations. What makes this process unique is that the benefit of cleanliness does not come alone. You can expect a significant reduction in sheet breaks, lower energy consumption, along with huge freshwater savings and reduced misting, amongst other benefits. For tissue machines, this technology can be used for wire and press fabrics with the same results as indicated above. In those applications, a single cleaning head will deliver water up to 2,500 PSI, through 24 linear jet nozzles with no mist created. Paprima’s Power-Jet system is a direct replacement of the existing oscillating high pressure showers, even if they incorporate a mist elimination system. The typical return on investment of a complete system is between 3 to 6 months.
It all makes sense Paprima has been at the center of high-pressure development for the paper industry since 1986, leading the industry in water-jet turn-up and on-machine trimming systems. It was only logical for us to move into high-pressure cleaning systems, even if their operating pressures are only a fraction of our traditional cutting equipment. ●
■■ The head design is at the core of the Power-Jet™ Cleaner’s efficiency and based on Paprima’s extensive experience with high-pressure water jets.
PAPRIMA INDUSTRIES INC. 75 Guthrie Dorval (Montréal) - Québec H9P 2P1 - Canada ■ website: www.paprima.ca ■ phone: +1 514-422-9555 ■ email: email@example.com
READY FOR A NEW EXPERIENCE?
INNOVATION, RESEARCH AND SERVICE SABA Automation realizes customized solutions for end of line, thanks to its innovative technology.
S.A.B.A Automation S.r.l. Via della Fisica, 25 41024 Spezzano di Fiorano (MO)
T: +39 0536 92 0907 E: firstname.lastname@example.org
Towards energy-efficient and economical Tissue production with
â&#x2013; â&#x2013; EP Turbo Blower is a key element in the RunEco solution.
Engineered solutions for pulp and paper industry worldwide 126
Runtech RunEco solution is a fully adjustable, energy-efficient vacuum system for tissue production. It’s a tailor-made solution equipped with optimal save-all and doctoring system and online dewatering measurements. RunEco can provide energy savings of 30 to 70%, and is applicable for both greenfield and rebuild projects. by: Tero Pärssinen, Technical Director and Jussi Lahtinen, Sales Director, Runtech Systems.
acuum is an expensive tool and often excessively used; one of the top three energy consumers in a paper mill. With increasing cost of energy and environmental awareness, paper mills are demanding reduced specific energy levels and operational costs to help with their competitiveness. Runtech RunEco vacuum system is developed especially to take into account the challenges and demands related to the dewatering and runnability. Traditional method of increasing vacuum levels is replaced with speed adjustable turbo blowers, optimal doctoring and save-all systems with online dewatering measurements. By using only the needed vacuum in the critical consumers, mills can fully benefit from the more efficient nip dewatering strategy and save energy.
Reliable dewatering - the basis for runnability Each vacuum element in the machine requires a certain amount of air flow to operate at an ideal vacuum level i.e. at the minimum to maximize the energy efficiency while maintaining the runnability and dewatering capacity. The needed capacity is dependent on felt life and type, paper grade, basis weight, machine speed etc. To achieve this challenging goal we need reliable dewatering measurements. Runtech EcoFlow™ meters are designed to measure water flow across a mechanical restriction and are not sensitive to entrained air or foaming.
▼▼Operating window comparison.
RunEco solution - operating principles EP turbo blowers are designed to operate efficiently across a wide range of vacuum levels and air flows. It allows mills to optimize vacuum levels whilst taking advantage of the higher efficiency a blower has over a traditional liquid ring pump device. High speed motors, driven by frequency converters, allow a typical RunEco blower to provide paper machine vacuum levels between 30 and 70 kPa. A wider range of impeller designs allows highly efficient levels across the operating range. This means that the amount and the usage of throttling valves can be reduced to a minimum. The result is energy savings of 30% to 70% when compared with traditional vacuum systems.
in dryness after the press section which saves considerable amount of energy in the dryer section (4-12% less steam).
Tailor-made RunEco solutions no compromises
▲▲Comparison of single and two-turbo systems operation and efficiency.
Dewatering and doctoring are not only related to energy consumption, but also play a major role in paper machine runnability (profiles), efficiency (dirt and breaks) and profitability. Therefore, a well-designed and operated dewatering and doctoring system is one of the key issues to a well-performing and energy-efficient machine. The most economical method of water removal in a press section is nip dewatering. Fit-for-purpose doctoring and save-all equipment allows the felts to run wet
3 x Liquid Ring Pumps
1 x Turbo
2 x Turbo
Typical power consumption
Energy costs/year 70 EUR/MW
1,400,000 EUR 140,000 EUR
2,700,000 EUR 270,000 EUR
TCO for 10 years Saving/10 years Saving/year
▲▲Table 1. Typical calculation, including a long term cost of ownership, comparing the costs of a single and two turbo unit RunEco system to a traditional vacuum system with liquid ring pumps.
collecting water in the pans enabling higher dewatering, higher felt lifetime and better moisture profiles to improve runnability. Suction rolls are often equipped with double doctors to prevent re-wetting and maximize void volume to allow best water removal. Save-all pans should be designed to manage the water that is removed from the nips, and engineered to be rigid enough to accommodate doctor holders. Runtech is one of the leading suppliers for the improved dewatering and doctoring solutions for all kinds of paper machines. In many cases, Runtech’s solutions have led to a 1-3% increase
Depending on Tissue machine design and width the most efficient operation sometimes requires one and sometimes two Turbo blowers. The specified air flow capacity is typically quite high consisting of overall safety margin, felt life and type margin and with liquid ring pumps e.g. pump wear and seal water temperature variation margins. In normal operating conditions the needed air flow capacity is ~40-50% lower than the specified capacity. Regardless of the situation, RunEco system with a fully speed-controlled turbo blower provides high operating efficiency at all times. During normal operation one single-stage turbo blower typically provides sufficient capacity. However, a system with two turbo units allows even higher operational flexibility, controllability and energy efficiency. Table 1 shows a typical calculation, comparing the costs of a single turbo unit and two turbo unit RunEco system to a traditional vacuum system with liquid ring pumps. The absolute difference is naturally related to the local energy price. However, the table highlights the fundamental differences in the running method, controllability and losses between the systems. With years of hands-on papermaking know-how, Runtech develops, designs and supplies equipment and related services for paper, tissue and pulp mills. Hundreds of delivered systems, such as dewatering meters, vacuum systems, tail threading equipment and doctoring solutions benefit our customers by enabling energy-efficient and economical production. The integrated solutions result in significant operational cost savings, improved machine runnability and product quality, giving a competitive edge for the customers in the market. ●
RUNTECH SYSTEMS Kastarintie 25 35590 Kolho - Finland ■ website: www.runtech.fi ■ email: email@example.com ■ contact person: Mario Battiston, Sales Manager ■ phone: +39 335 6211829
MICROLINE Packaging & Automation
The machines speak:
â&#x2013; â&#x2013; The machine speaking.
Decades have passed since the paper converting machines were moved by a single belt driven by the power of water or the steam of a boiler. Nowadays, the latest generation processors are used that control all the various machine functions in real-time and produce thousands of data every day that often no one takes care of interpreting, processing and using to improve the quantity by: AFD Antica Fabbrica Digitale Srls and quality of production. 130
let’s listen to them
o date, the management software and those on the machinery have not walked on parallel tracks. While office software followed the development of traditional operating systems with Windows or Unix, the PLCs of the machines developed with proprietary operating systems not suitable for interconnection with traditional systems. This led to the creation of technicians with
■■ Tracepaper - Data flow.
distinct professional paths that poorly interfaced with each other. It is no coincidence that in many companies you can still see PCs where the operator enters the production data of the machines “by hand”, ignoring the thousands of information that the machine could send directly and in real time to the management system. A picture emerges which reveals the poor functionality of the machines and it is them that complain about it or rather the work-quality relationship. Lately, however, thanks to tax incentives and the technological development of the electronic devices that are mounted on the machinery, the sensitivity to improve the development of this sector is increasing.
We at AFD in collaboration with Infosigi, a company that develops tailor-made MES, have created PAPERTRACE a software capable of translating data, which arrive from the machine, into a language understandable for the production, administrative or assistance manager. In our latest order we connected four machines from different manufacturers, with electronic systems that are also very different from each
We are not just a technology supplier but above all, we listen to and implement the ideas of entrepreneurs that look ahead
other, all using a server with an MSSQL database that records the data from the machines by making them available to PAPERTRACE and management software. The innovation we made has made it possible for the management system to send the various production orders to the machines and to check their progress. The recorded data become the machine history and thanks to these it will be possible to: plan the machine changes taking into account the production times, the orders made, for their better optimization. Analyze machine downtime to plan preventive maintenance or try to eliminate the various bottlenecks that will be highlighted by the analysis of these data.
he province of Lucca has been considered as the main European area for the paper industry, and among the more important in the world. The “Paper dust” has entered into all economic sectors of our industrial fabric, as has the story of AFD, which was born out of this dust. We started working at companies that were building machines for processing, when electronics and automation was in its infancy. We saw the first @ AFD PLC on-board machines, instead of the old relay logic, the programming of the first axis controls and of the first industrial networks. In 1989 we created the first electronic “Pressina”, and participated in the Gemini project, the first converting machine with dedicated axis controls and first-generation brushless motors. In 1995 we started to manufacture interfolder machines, that were recognised as the fastest and most productive on the market. In 2007, AFD was born, giving rise to machines such as the I-Jet500 for industrial roller and interfolding IMFOLD. Currently we are working with several transformers around the world. Finally, and the most important thing, we are not just a technology supplier but above all, we listen to and implement the ideas of entrepreneurs that are looking ahead.
■■ Tracepaper - Hardware configuration.
■■ Tracepaper - Logic configuration.
Calculate the cumulative value of the line efficiency (OEE: performance, availability and pieces produced) in real time. It is also possible with additional software modules (labeling of finished products and raw materials) to automatically manage traceability. Finally, to make PAPERTRACE independent of the various hardware and software platforms, a simple browser such as Chrome or IE Explorer is used to show the data. The data can then be viewed on tablets, mobile phones or PCs without being tied to any type of hardware.
PAPERTRACE is a flexible software that can be interfaced, with commonly used software tools, with any type of PLC or axis control to always be one step ahead of the competition. ●
AFD ANTICA FABBRICA DIGITALE SRLS Via Pacconi 78i 55016 Porcari (LU) - Italy ■ website: www.afdcom.it ■ phone: +39 393 8373758 ■ email: firstname.lastname@example.org
experience the alternative “Without change, there is no innovation, creativity or incentive for improvement.Those who initiate change will have a better opportunity to manage the change that is inevitable” William Pollard
www.mare.com - email@example.com - firstname.lastname@example.org - 02 90326.1 - 0572 427208
Packaging in line
■■ High speed case packer for AFH Rolls.
with your products
ac Due has completed the transition from a family business to management company, maintaining the dynamic approach and strong innovation traditions that have characterized the company during its 40 years history. Today it is present in the market as a structured group, able to follow all the different customers’ needs all over the world. The key part of this transition was the creation of on-site supports that guarantee a significant improvement both in sales and technical assistance. Today Mac Due group is present in the United States, Poland and Spain. Currently, more than 7,500 equipments are installed worldwide. This important number is not only the result of a more modern corporate reorganization in-line with market needs. First of all, the result of the work of a highly specialized team of professionals carefully selected for their technical skills and human qualities. Our native speaking commercial technicians help us to
Consumers needs change constantly pushing the packaging business to a constant evolution and companies are forced to change their production approach in order to answer in the best manner to the market needs. Transformation of Mac Due is taking place in this exact contest of continuous renewal. by: Mac Due Srl
ensure maximum result on communication between Mac Due and the final customer at every stage of the project. Over the past 10 years, our key point has become to provide complete solutions, capable of managing every part of a packaging line. The keyword is “growth”, in the distribution of products and in responding the customer needs. That is why we are able to supply complete solutions, including flexible and high-performance case packers and palletizers island. The product processing in our lines take into consideration all the steps, with particular attention to the handling and final quality result. The expansion of our company is not only geographical. The innovative drive has guided Mac Due in almost forty years of activity and it is far from the end. We are currently expanding the business of interest, developing new solutions for products such as diapers, facial tissue and interfolded. It wouldn’t happen without continuous innovation. It is a well-known tendency, when players in the packaging world are easily losing
■■ Fiorenzo Donetti, Mac Due’s Managing Director.
The vision: being a model of performance and technological innovation in the packaging industry
dynamism concentrating efforts only on sales. A distinctive feature of Mac Due is the continuous research for finding most effective technological solutions, created from the collaboration between various business units. This can be seen from the commitment to apply new control tools and automation into the machines, as well as in the constant improvement of their strength and durability. In this sense, we are concentrating our efforts on the implementation of IoT systems capable of simplifying the management of the lines, monitoring of performance and scheduled maintenance. At the same time, the ability to monitor the operation of the machinery and real time inspection without concern of production and safety risks. Therefore, we are implementing intuitive vision systems that will facilitate even more the use of the lines. We are constantly working to optimize Mac Due machines, making them easier to use and
▲▲Customized Palletizer Island for AFH and consumer rolls.
▼▼Bundler machine for diapers.
MAC DUE SRL Via Seragnoli 12 40138 Bologna - Italy ■ website: www.macdue.com ■ phone: +39 051 6014523 ■ email: email@example.com ■ LinkedIn: linkedin.com/company/mac-due-automatic-packaging-machines
in-line with customer needs. A very important step was the creation of Mac Due Kit, a reality dedicated to management stand-alone machines that we call “standard”. Collaborations in different areas of the world have allowed Mac Due Impianti to make the distribution of customized products increasingly widespread. In the company transformation, we have included the expansion of communication activities and skills sharing. Our presence on strategic channels such as LinkedIn has been increased, creating communities of packaging specialists and regularly organizing Open House events. For your information, the particular situation caused by Coronavirus prevents us from having guests, therefore the 2020 edition will be available on our Vimeo channel. In a constantly evolving business environment such as packaging, Mac Due moves quickly to anticipate market needs and respond with a modern organization that focuses on innovation and constant assistance. ●
IM is a family owned specialty chemical company supplying the pulp and paper industry. We focus on creating more value from fewer resources to use the world’s limited resources more efficiently.
BIM in brief Pulp and paper focus; founded in 1973; approx. 200 employees worldwide; certified according to ISO 9001 and ISO 14001; member of the UN Global Compact; Gold rated by Ecovadis; associated with the Responsible Care Program.
Your challenge, our mission The unique knowledge of pulp, paper making and converting, makes BIM the perfect partner in developing sustainable tissue products.
The company provides a full range of chemical solutions and services to optimise performance and value. BIM has over 40 years’ experience of tissue applications. Whatever the problem, we find the solution. In 2017, a new lotion and balms plant was installed at our facility in Bolton - UK, to meet increasing customer demands. We’ve seen an increased demand for specialty lotions and balm solutions and this investment keeps us well equipped to produce higher volumes. This manufacturing flexibility makes us a reliable partner to cover all tissue making and converting solutions. Our microbiological and formulation laboratories specialize in customising and developing customer specific products in niche areas. Producing tissue with the right softness, strength and bulk is a balancing act. In today’s highly integrated but
BIM provides services and concepts all over the world through a global network of experts, by: BIM Kemi production units and R&D facilities. still very competitive global tissue industry, there are two important needs for a tissue maker: improved tissue quality with maintained machine productivity; better machine productivity without sacrificing quality.
Paper making and converting are integrated processes - BIM connects the two Our company was founded in fibre modification. We have a comprehensive portfolio of process chemistry including â&#x20AC;&#x153;greenâ&#x20AC;? machine hygiene packages, strength agents and deposit control aids. The uses of chemicals have a relatively small impact when we consider paper productions cost structure. However, they have an important part to play in the overall process from furnish to finished product
in terms of their contribution. The ability to network different technologies to the benefit of machine productivity and finished product quality is a high priority for BIM as a chemical supplier. We have the knowledge and competence to understand the papermaking process and implement complimentary chemical treatments to ensure minimum interference and interaction with each other and to maximise their impact on cost efficiency and paper quality. We can deliver expertise for both papermaking and converting by our problem-solving skills, fast response, tailor made solutions and innovation approach.
Adding value and softness to tissue In the modern consumer world, the sensory feeling of tissue is of paramount importance.
Together with our customers and partners we will contribute to make life on earth more sustainable, healthy and inspiring
Therefore, one of the most important quality factors differentiating tissue products is softness or surface feel, particularly for grades such as facial and bathroom tissue. Other functional properties with respect to the grade produced, such as absorbency and strength, are equally important and should not be sacrificed in its pursuit. An understanding of how to enhance and quantify softness is critical to ensuring these criteria are met. Softness is therefore essential for tissue products and whilst creating softness is hard enough, measuring it can be equally challenging. The perceived softness of the tissue can be controlled by fibre selection, the forming and creping section, as well as external use of chemicals to enhance quality. Together with the chemical supplier, the tissue maker can apply an objective approach to process and product development.
Looking for your niche? BIM can support you to personalise your tissue portfolio. Our products are continually developed to provide further quality enhancement to comply with all required regulatory constraints whilst retaining all other desirable properties. We can tailor make a speciality surface application just for you.
Process optimisation - a game breaker for converters Clean running and operational efficiency have become increasingly important in today’s competitive arena - making more of less! But no two base sheets behave in the same way. We know this and understand that the market demands differentiation. This is our specialty, so challenge us at BIM. BIM has a wide range of technologies to ensure maximum machine productivity. ●
BIM KEMI ■ website: www.bimkemi.com ■ email: firstname.lastname@example.org ■ contact person: James Hudson, Tissue Segment Leader ■ email: email@example.com
thereâ&#x20AC;&#x2DC;s no change without a change As of now, SENNING supplies. paper-based packaging solutions. Quality and Sustainability.
Christian Senning Verpackungsmaschinen GmbH & Co., KG . Bremen . Germany . +49 421 69 46 2-0 . www.senning.de
vacuum pumps and systems, formerly CUTES Europe Ltd. has specialized in optimizing existing vacuum systems in the paper industry Optimum design, good condition of the vacuum pumps and smart control of the vacuum system are crucial for the efficiency of the paper machine for its reliability and for the energy efficiency. by: VAKUO GmbH vacuum pumps and systems
uuVAKUO CE1 vacuum pump.
he 50% energy savings are possible. Following simple measures, the rotating speed of a vacuum pump can often be reduced by 30% (x 0.7) and thus the power consumption by 50% (as 0.7 x 0.7 = 0.49). Since the 1990s, we have often reduced the specific consumption and saved 50% of energy by replacing liquid ring pumps, often 25 years old, with new liquid ring pumps. This energy saving is more relevant today than ever before. VAKUO manufactures two types of liquid ring vacuum pumps - radial distribution with cones or axial distribution with port plates as well as radial fans and Roots blowers. Simple questions like “how much vacuum do we really need, and when?” or a measurement of the pump actual capacity lead to good practices and sustainable energy savings.
in pressure drops and increased electrical consumption. A wrong response would be to increase the rotating speed to compensate for the loss of capacity: high tip speed means poor efficiency, and also more wear and more maintenance.
10 important topics for a better reliability and lower operating costs
A system with dedicated pumps for each area is more adaptable and efficient and avoids expansion, which can cause a loss of performance.
1. When to replace a vacuum pump? We recommend testing the performances of each pump regularly, ideally every year. We offer audits including on-site performance tests and endoscopies. Measurement and analysis of the results are the first essential step towards optimization. 2. Repair or replacement through a new or swap pump?
4. What is the expected efficiency of a pump? 1 kW per m³/min is our benchmark, it is the specific consumption for properly sized pumps in good condition. Liquid ring vacuum pumps taking advantage of the condensation effect, can easily reach this efficiency. If the system was properly analysed and designed, liquid ring pumps, turbo blowers, high speed fans, roots blowers… will all reach the same efficiency - with various advantages and disadvantages. 5. Central system or dedicated pumps?
50% energy saving using your existing systems with liquid ring pumps
As important as the question if the pump is in good conditions, We have to ask and check if it is the right pump (adequate size) for your actual effective needs? Each 100 kW pump can save or waste up to 30 kW. The extra costs or potential saving are high: 30 kW x 12.5 ct/kWh x 8,000 h/a = 30,000 €/year. 30,000 € is approximately the price for a new pump of this size, the price for repairing or replacing a pump is negligible compared to the annual energy savings. 3. Why does the efficiency of the pumps decrease over time? Wear, due to corrosion or abrasion affect the critical clearances and result in lower flow. Also the deposition of fibers, scale or limestone clogs the inner channels, resulting
uuVAKUO CVP type vacuum pump.
6. With pre-separator? Vacuum pumps (compressors) are designed for pumping air or steam and not for pumping liquids. Liquid ring pumps are robust but very inefficient when handling liquid: the energy consumption and the wear increase. A pre-separator improves efficiency and maintenance intervals. 7. Energy saving with cooler/colder water? Yes, but not directly. Using a colder water, only increase the suction power of the pump. This increase in flow makes it possible to reduce the speed. We save energy by reducing the speed, i.e. by replacing the small motor pulley or installing a frequency converter. Cold water alone is not enough. ttVAKUO CNN pump (conical design) with dismountable bearing brackets. Vakuo vacuum pumps are interchangeable with other brands, they are “bolt-on” replacements (same performances, same dimensions) but offer many features/advantages like for example the removable bearing brackets.
8. Port plates (axial) or cones (radial)? Both designs have pros and contras - VAKUO offers both: conical pumps are more robust and more efficient when we take advantage of larger ports to recycle more water, get a lower ring temperature and a better efficiency.
Flat sided pumps (with port plates) are more versatile and adapt better to different vacuum levels. VAKUO has also launched the CNL Series combining conical design (larger ports) with the plate valves (adapting to the vacuum level and saving energy) like in the flat-sided pumps. 9. Are liquid-ring pumps capable of operating at variable speed? Yes, especially liquid ring pumps benefit from the above-mentioned lever. The suction flow is proportional to the rotating speed, while the absorbed power increases (or decreases) exponentially. We can achieve high energy savings by adapting the suction flow (rotating speed). 10. What is the next step? Call us now. Every day VAKUO analyses vacuum systems in the paper industry. By combining our experiences and knowledge, we will optimize your existing vacuum system. ●
VAKUO GMBH VACUUM PUMPS AND SYSTEMS ▲▲VAKUO CKD drain pumps or extraction pumps are “work horses” designed to drain the pre-separators under a vacuum up to -80 KPa. Pre-separator and extraction pump are key components for an efficient vacuum system.
Max-Planck-Str. 9 61381 Friedrichsdorf - Germany ■ website: www.vakuo.com ■ email: firstname.lastname@example.org ■ contact person: Dipl. Ing. Pierre Strauch ■ phone: +49 6172 137 132 - +49 173 670 8558
NEED TO CUT THE ENERGY COSTS OF YOUR
PAPER PRODUCTION? MAYBE IT’S TIME TO RE-THINK YOUR ENERGY USE. Centrax provides a range of gas turbines that can solve your energy production needs or improve the efficiency of your existing CHP plant. This is better for the environment and better for your profits. What’s more, Centrax provides a complete package of expert maintenance and customer service – leaving you to take care of your business. So as well as saving energy at your plant, we save your team’s energy too. We’ve designed and installed gas turbine power packages for over 70 years. Our products range between 3-15 MW and have earned a reputation for being clean, modern and efficient. They could transform the way your paper plant uses power.
CENTRAX. GENERATING TRUST.
LEARN MORE centraxgt.com +44 (0)1626 358 000
An instrument that has been conceived in the spirit of green economy considering 4.0 Industry, continuous improvement, environmental protection, energy saving, production efficiency, work safety and company profit. by: Binet sul Liri SpA
▲▲ In the control room a dedicated computer displays the scrolling of the sheet with eventual defects.
INVISION DEVICE comes from the idea of supporting tissue paper manufacturers to trace the critical points on Pick-Up or Crescent former felts that generate defects on the paper sheet. Moreover, with the current and mostly future environmental and green economy regulations, no paper mill will be able to avoid to adopt a system that saves energy and economic resources and limits environmental damage, if such a system is available, as well as no paper mill can currently refrain from dealing with their discharges not only for an economic and environmental issue, but also because expressively imposed. The BINVISION DEVICE system consists of a number of high-definition and high-speed cameras that monitor the sheet of paper outcoming from the Yankee cylinder and before the pope. The sheet is also illuminated in transparency to simplify the work of the cameras. Whenever a defect/hole is detected, the system generates an alarm in the control room and on the dedicated computer screen you will be able to see the systematic defect as it flows, its shape and size, its transversal and longitudinal position. A local washing accessory can then be therefore activated and the system should be positioned exactly on the transversal band where the defect occurred and this band must be washed sucked out locally over a width of 5 cm. If the defect disappears, all is good, otherwise a quick stop of the machine at the end of the reel should be made and the system will thus be able to identify on the felt, in a designed and accessible area
Right from the start, our goal has been to produce the best quality clothing for paper machines ttThe camcorder detects any defect on the sheet before the pope.
ttThe area on the felt illuminated by the tracking projector containing the critical points.
Our inspiring philosophy is to transform the art of manufacturing felts in an exact science
▲▲The image of the critical point on the felt illuminated by the tracking projector.
BINET SUL LIRI SPA - ENGINEERED FABRICS Via Nicolucci 11 03036 Isola del Liri (FR) - Italy ■ website: www.binetsulliri.it ■ phone: +39 0776 808407 ■ email: email@example.com ■ contact person: Eng. Marco Viscogliosi, President - General Manager
for the operator, the critical point that generated the defect/hole, which is highlighted on the felts’ surface by a particular tracking projector by projecting onto the felt surface a luminous zone with a diameter of about 20 cm inside which said critical point is certainly contained. The visual examination of the point will make it possible to understand what it is and which treatment will be mostly appropriate, with mechanical, chemical or water cleaning means, but still limited to the point in concern, for a very short time and in an absolutely decisive way. The intervention time is estimated at around 5 minutes for cleaning the critical point and 10-15 minutes for the machine work stoppage. Furthermore, the synergy effect between the localized washing system and the continuous monitoring of the paper sheet, ensures prompt intervention and solution right from the beginning of any defect, even before proceeding to stop the machine. Additionally, with our system, each reel will be certified in a qualitative point of view and should there it be any type of defect, either random or systematic, this will be exactly indicated in quantity, shape, size and position. The BINVISION DEVICE system has been developed by Binet sul Liri SpA and Vision Device Srl and the patent application is filed. ●
Choose Infinity for your sustainable tissue packaging solutions. to an Infinity Wrapper…
From the Earth…
to your customer…
and back again…
Production tested options from Infinity: Infinity Wrapper with Heat-Sealable Overwrap - Partnership with Little Rapids Corp. to develop and test ECOVA Paper Overwrap. - 100% plastic-free - Production tested on Infinity packaging line - Recyclable solution - No glue system required - Made with 100% recycled fiber Infinity Infusion 3.1 – Patented modular machine system for production flexibility. - Industry proven solution - Easily switch between bundling, bagging and casepacking - Phase out poly over time
See more at ecovapaper.com or watch Ecova Paper in production on YouTube!
Second Hand Machines
A Matter of Trust
here are many reasons in favor of taking advantage of a specialized dealer. However, one thing can be considered to be the most important factor for both the seller and the buyer of used equipment: the trust they have to give towards the dealer. There are many kinds of dealers in the market. However, few are specialized and focused on the comparatively small, yet growing tissue and towel industry only. The majority of dealers cover a wide range of machines and applications which go beyond tissue converting machines. It appears, that they might have access to a greater number of customers and potential buyers, but you have to bear in mind that these customers are also active in divergent markets. Moreover, they may also lack the knowledge about the rather
specialized converting equipment that can be found in the tissue industry, and its players. Therefore, both the seller and the buyer have to trust the dealer with regard to knowledge, reliability, confidentiality, market coverage and networking. Two of the most trusted dealers in the tissue industry are TISSUE TEC Sales & Service GmbH and SERVIPAP.
Motives for Sellers and Buyers At first glance it seems that the owner of surplus equipment is pursuing a different goal than the potential buyer of this equipment. Obviously, it will be his aim to achieve the highest price possible for his equipment, while the potential buyerâ&#x20AC;&#x2122;s priority is to acquire it for the lowest amount possible. The sellerâ&#x20AC;&#x2122;s second motive is to dispose equipment that is no
■■ A complete PERINI/CASMATIC bathroom tissue/kitchen towel rewinder line supplied in 2019.
■■ A complete PCMC/TMC bathroom tissue/kitchen towel roll line supplied in 2019.
A considerable percentage of used converting equipment changing hands in the tissue industry is sold by second hand machinery dealers such as TISSUE TEC Sales & Service GmbH and its partner company SERVIPAP. by: TISSUE TEC Sales & Service GmbH
longer required for many reasons. The motives of potential buyers to search the market for used equipment can be manifold. The most obvious reason is the financial aspect, as a good number of converters simply cannot afford to acquire new equipment. The second reason is time, as usually used equipment is immediately available. The third reason, which applies quite often, is that with a used machine a converter can test the market acceptance of a new product without a significant investment in a new line. However, their common goal is to do business based on the equipment available on the second hand machinery market, so one of the primary tasks of TISSUE TEC Sales & Service GmbH and SERVIPAP is to preserve the interests of both parties and to handle their projects accordingly. Lastly, a trusted machinery dealer has a
global reach that many brokers or sellers do not have at hand. Proof of this is shown in recent projects managed by TISSUE TEC Sales & Service GmbH and SERVIPAP covering the following regions from origin to destination: Complete Industrial Rolls Line from Spain to USA; Complete Industrial Rolls Line from United Kingdom to Mexico; Napkin Wrapping Machine from Germany to USA; Complete C-Fold Handtowel line from Finland to USA; Bathroom Tissue Wrapping Machine from Colombia to Dominican Republic; Bathroom Tissue Wrapping Machine from Hungary to Ecuador; Bundling Machine from Australia to Jamaica;
One of the most trusted dealers in the tissue industry is TISSUE TEC Sales & Service GmbH
■■ Another complete United Converting industrial roll rewinder line supplied to the USA in 2019.
■■ A complete United Converting industrial roll rewinder line supplied to the USA in 2019.
Complete Bathroom Tissue/kitchen Towel line from Italy to South Africa; Two Complete Industrial Rolls Line from United Kingdom to USA; Complete Bathroom Tissue Line from Italy to Ecuador; Complete Bathroom Tissue Line from United Kingdom to Dominican Republic.
The Job of a Dealer Acting to the benefits of both the seller and the buyer requires knowledge about the technical configuration of the equipment, the products that can be manufactured on it, but also the future availability of spare parts, the potential extensions/modernizations and, last but not least, about the marketing possibilities and the obtainable price. The seller needs to trust the dealer for a realistic appraisal of the equipment’s value, its marketing prospects, and also that the dealer respects certain sales restriction that may apply. The potential buyer, on the other hand, needs to trust the dealer that he is sincere about the equipment, in particular with regard to the scope of supply, the products it produces, and its condition. Behind the scenes, for a dealer there is a lot more to consider, prepare and actually do than both the seller and the buyer normally recognize. In addition to the above mentioned
skills and knowledge, TISSUE TEC Sales & Service GmbH and SERVIPAP are also providing the full range of service such as machine relocation (including disassembly, transportation, re-assembly and all customs documents), refurbishments or intermediate storage. In the past, we have successfully realized the sales and relocation of numerous converting machines, sometimes under difficult circumstances, e.g. by taking out two complete pocket handkerchief lines out of the 4th floor of a high-rise building in Hong Kong. Due to 30 years of experience in the tissue industry, the key people of TISSUE TEC Sales & Service GmbH combined with the synergies of SERVIPAP exactly know their customer’s demands; they are capable to satisfy the needs and expectations of both sellers and buyers of used equipment. Their knowledge covers bathroom tissue and kitchen towel rewinders, industrial roll rewinders, napkin and pocket handkerchief machines, handtowel and facial tissue folder, packaging machinery, upgrades to existing lines and spare parts. For any request regarding used tissue converting equipment, TISSUE TEC Sales & Service GmbH and SERVIPAP are reliable partners in the tissue industry. Second hand machines - a matter of trust which can be relied upon to achieve the best conclusion for both the seller and the buyer. ●
TISSUE TEC SALES & SERVICE GMBH In der Birk 9 41542 Dormagen - Germany ■ website: www.tissue-tec.de ■ phone: +49 2133 9771616 ■ contact person: Wolfgang Tillmann, Managing Director ■ mobile: +49 172 6817338 ■ email: firstname.lastname@example.org
TOGETHER FACING CHALLENGES TO SPRING UP AGAIN
SUPPORTING YOU WITH PASSION. EVERY TIME. Even in these challenging times Amotek has been always able to react efficiently. Amotek stands strong as a reliable partner and makes sure to act responsibly by giving the best support, its customers are used to get. Amotek has never stopped serving its customers to satisfy all requests and needs and will continue to support powerfully to spring-up again. Amotek is always at your full disposal and will never stop to support you with passion.
Amotek Sales & Service S.r.l. | Via Piemonte 5 | 40069 Zola Predosa | Bologna | Italy
NEW - Follow us on
▼▼From left to right: Mr. Toni Pérez, Sales Manager, Mr. Francisco Pérez & Mr. Carlos Rocamora, CEOs and Mr. Alan Rocamora, Financial Manager.
Paniker: where know-how and engineering united for the best adhesive solutions 154
With a 12,000 m2 facility, founded in 1922 and located in Barcelona, Paniker has managed to evolve its range of adhesives, to become the largest manufacturer of PVA adhesives by: Paniker SL in Spain.
Engineering in adhesives
rancisco Pérez, Chemical Engineer and General Director of Paniker for more than 30 years explains that “in the beginning, Paniker specialized in solvent-based adhesives for the footwear industry, but over the years, we diversified in markets such packaging, labelling, insulation, automotive and tissue”. Nowadays, the R+D+I Department is made up of specialized engineers trained in each sector of the market, who can adapt the products to suit the needs of their clients. The company has also invested in a new production plant specifically for tissue adhesives, which has allowed them to optimize production processes so that their clients can benefit from short delivery time. With a total production capacity of 44,000 tons/year, Paniker’s industrial products are currently utilized in more than 25 countries around the world. “We provide our clients with the know-how to solve their bonding problems,
▲▲Mrs. Ruth Castro, one of our Chemical Engineers.
■■ View of one of Paniker’s production plants.
as demonstrated by the growth in the tissue market. For example, the performance of an adhesive in hot and humid climates is not the same as in cold climates; therefore we are technically prepared to provide specific solutions for each case”, says Francisco Pérez.
Adhesives for converting: the tissue range Throughout all these years, Paniker has been able to develop a complete and wide range of adhesives for Lamination, Pick Up, Tail Sail and Tube Winding, which are perfectly adapted to the needs of the market and comply with the FDA/BFR Regulations. Under TISSUECOL brand, the 900 ’range developed for Lamination offers high dilution capacity and provides smoothness to the paper. Adhesives for Pick Up applications - TISSUECOL 910’s and Tail Seal TISSUECOL 200’s - offer the possibility of use from the first to the last piece of paper. Regarding the application for Tube Winding, EUROPANOL 8500’s adhesives are perfectly adapted to different application systems, both for slow machines and fast machines, capable of reaching speeds of up to 120-150 m/min, and for tubes of 1.2 or 3 sheets. Fernando Martinez, Engineer Responsible for Research, Development & Innovation of Water-based adhesives, highlights that “one of the advantages of using our adhesives for tissue is cleaning, both in application and machine adaptability. This is something that the market has always demanded and that we can technically provide”. Furthermore, Paniker produces a range of Boric-free adhesives suitable to new market needs. ●
The strength of a group. Since 1991 Paniker has become part of the Beardow Adams Group, a world leader in the manufacturing of industrial adhesives. It has 7 production plants around the world and BRC, ISO 9001 and 14001 certifications. For Mr. Pérez “we are proud to belong to the Beardow Adams Group, where the quality of the adhesives is hallmark in the market”. Quality service. “In such a competitive sector and competing with large multinationals, Paniker offers personalized attention, ease of contact with our Technical Department and short delivery times. These are some of the reasons why our clients feel so comfortable working with us”, says Mr. Francisco Pérez. The Green Team. Paniker is a company very focused on caring for the planet, and respectful of the environment. In the words of General Manager, “at Paniker for some time we have been working in the line of Sustainability, proof of this is that we have a work group named Green Team. Their focus is to increase environment awareness of all staff, as well as collaborate with our suppliers looking for biobased raw materials or less polluting packaging for the planet”.
PANIKER SL Carretera de Barcelona a Santa Creu de Calafell Nº 68 08830 Sant Boi de Llobregat (Barcelona) - Spain ■ website: www.paniker.com ■ phone: +34 936402116 ■ email: email@example.com
Generating trust with clean, efficient power generation
Looking to extend the life of your power plant? Need a repowering and renovation partner who has a wealth of experience in existing gas turbine installations? Who can renovate not only their own equipment but other manufacturers’ too? Maybe it’s time by: Centrax Ltd to talk to Centrax Gas Turbines. ■■Centrax Limited headquarters in Newton Abbot, UK.
entrax Gas Turbines offers a range of power packages using up-to-date technology that can be used in combined heat and power (CHP) which is ideally suited to paper production - making it better for the environment and better for profits. Centrax has designed and installed gas turbine packages for nearly 60 years and understands the importance of generating reliable and efficient power. Which is why it has invested in a comprehensive service system throughout Europe and Russia - to provide local support and maintenance, ensuring that units are in optimal condition and leaving customers free to take care of their core business. All of Centrax’s generator packages use reliable, high-performance Siemens core engines, and with power outputs ranging from 3 MW to 15 MW, packages can be scaled to match customers’ specific needs. This power range is ideally suited to the demands of paper production with packages offering excellent operational flexibility. In Italy, Centrax Gas Turbines has supplied Favini Srl papermill with a CX501-KB5 high-efficiency cogeneration power plant. The indoor unit provides 3.8 MW of electricity plus 23 tonnes per hour of saturated steam used in the papermaking process. Favini benefits from Centrax’s in-country customer support centre which services the unit as part of a comprehensive maintenance contract. Another CX300 8.5 MW is powering Ahlstrom Munksjö, Saint-Séverin, France, a
entrax Gas Turbines specialises in the manufacture and service of gas turbine-powered generator sets ranging from 3 MW to 15 MW that use core engines from Siemens. The generator sets are used mainly for combined heat and power but also in base load, simple cycle and standby applications. It is a global company with a broad customer base throughout the world. Centrax has invested in a comprehensive service infrastructure that has earned it an excellent reputation in customer support leading to a 100% customer loyalty in maintenance contracts. This assured after-market care supports the lives of units and maximises revenues for its customers throughout the life of the generator sets.
ttCX300 installation at Ahlstrom Munksjö, Saint-Séverin, Charente, France.
What really fuels us at Centrax is a commitment to providing exceptional customer care with a personal touch world leader in the production of sulphurised paper for the food industry. The generator set powers the site and produces steam and electricity for the plant and its processes. One of Centrax’s longest-standing customers is Smurfit Kappa Roermond Papier in the Netherlands, who has been running four CX501 packages at its paper mill for the last 36 years. These units have been serviced by Centrax throughout. In 2015 the units reached a one million hour milestone, and a recent decision to upgrade the control panels to a state-of-the-art digital system was a vote of confidence for the longevity of the 501 engines. In 2016, Centrax Gas Turbines strengthened its
relationship with Smurfit Kappa with an order for two 5.3 MW gas turbine generator sets to, replace an existing CHP plant at a paper mill in the UK. The two CX501-KB7 DLE units are linked to waste heat recovery boilers to provide both electricity and steam for the paper manufacturing process. Unlike conventional power generation, CHP not only provides electricity but also makes use of the waste heat produced. This thermal energy can then be harnessed to create the steam, hot water and hot air needed in manufacturing processes. ●
CENTRAX LIMITED Shaldon Road - Newton Abbot Devon TQ12 4SQ - UK ■ website: www.centraxgt.com ■ phone: +44 (0)1626 358000 ■ email: firstname.lastname@example.org ■ contact person: Mike Roberts
we tiss you. new standards for tissue manufacturing and converting. For decades, the name SchäferRolls has been synonymous with outstanding performance where roll covers for tissue manufacturing and converting are concerned. Based on the experience gained through numerous successful applications, all of our tissue roll covers have been developed to comply with the special demands of the respective roll position, the specific product manufactured and the particular preferences of the machine operator. And we do all of this with the object of achieving new dimensions in the productivity, product quality and overall performance of your tissue production.
HybriFlex, P1, P40, tisQ, Q.dura. For pressure rolls, suction pressure rolls, embossing back-up rolls, marrying rolls, adhesive applicator rolls. Want to find out more about HybriFlex and other roll covers? Just ask the experts at SchäferRolls – we’ll show you how to optimize your tissue and converting machines.
SchäferRolls GmbH & Co. KG Benzstrasse 40 71272 Renningen, Germany T +49 / 7159-806-0 F +49 / 7159-806-300 email@example.com www.schaeferrolls.com
Precision all round.
BONETTI: High and Low Pressure Shower Solutions
Bonetti can boast a long experience in the supply of products for the creping application that dates back to the seventies: when it comes to its products, Bonetti is right now one of the major suppliers to the by: Bonetti SpA Tissue Industry worldwide.
ver the years Bonetti has helped numerous customers improve their creping process taking a comprehensive approach spanning from the blades to the doctoring equipment, them being both part of our product portfolio. Lately Bonetti has engineered and developed a complete range of High and Low pressure showers for the tissue, paper and pulp industry. The key component of these new products is the new developed
electronic linear drive BonSync (Fig. 1). BonSync electronic drive allows the oscillation of the shower used for high pressure cleaning of wires and felts and guarantees the best possible conditioning free of streaks, improving the quality of paper and extending the life of fabrics, felts and rolls. BonSync can be set at a very low oscillating speed, allowing the use of smaller diameter nozzles while minimizing the consumption of water and energy. In order to guarantee a perfect cleaning at all
Established in 1923 Bonetti has been successfully supplying the pulp and paper industry for more than 50 years
machine speeds, an electronic control cabinet has been developed for controlling the BonSync oscillator, ensuring a precise synchronization with the speed signal of the paper machine. BonSync Operating Program can be easily changed via the friendly touchscreen display even during running. Control cabinets can be supplied to handle single or multiple oscillators. To meet all cleaning demands of the paper machine, Bonetti offers three different shower models. Showers can be supplied with or
without internal cleaning brush, with manual or automatic flushing valves and with a wide choice of nozzles (Fig. 2). Bonetti is a worldwide leader in the supply of doctoring systems and blades. The portfolio offers a complete range of creping, coating and cleaning blades, in various materials and sizes. Focusing on the creping process, Bonetti’s offering includes both traditional steel blades in different grades and tip coated blades: MIZAR (Chrome Oxide) and SIRIUS (Chrome Carbide), compared to
▲▲Fig. 1: BonSync.
Bonetti’s success has always been based on a timely response to the needs and demands of the markets it serves
traditional carbon steel blades guarantee the superior performance requested by modern tissue machines. When compared to traditional carbon steel blades, they offer extended lifetime and greatly improve the softness of the sheet. These two blade qualities perfectly meet the demanding needs of papermakers: while MIZAR offers the longest possible lifetime, SIRIUS allows a smooth blade start-up, is not prone to chipping and can be machined with sharper angles suitable for Super Soft tissue grades.
Bonetti’s specialists can supply a complete audit of the doctoring systems and the blades in use. For doctoring systems the audit includes a geometric check of the mechanical condition of the doctors. For blades, the audit includes a check of all the blades used as well as an analysis of both existing wear and of wear pattern. The technical and sales team can offer all necessary information and assist you in the implementation of your machine to keep operation running at peak performance. ●
■■ Fig. 2: Shower Pipe.
BONETTI SPA Corso Europa 23 20020 Lainate (MI) - Italy ■ website: www.bonetti.com ■ phone: +39 02 935741 ■ email: firstname.lastname@example.org
Your trusted and proven partner Sulzer is the world leader in innovative and proven pumping and mixing solutions for pulp, paper and board industry. Our deep process and application knowledge together with a comprehensive understanding of market needs keeps us at the leading edge of technical development. With full-scale test facilities, we provide increased hydraulic excellence and unique applications coverage. We are committed to the development of new wood-based processes and applications. Moreover, we have deep knowledge in wastewater treatment and can offer great options for energy-efficient solutions. Contact us to discover your ideal pumping, mixing and service solution. www.sulzer.com
Profitable Solutions For Paper Industry
like no other
Fomat, systems and technology for paper mills ■■ Bruno Giannelli, founder and partner of Fomat.
Bruno Giannelli, founder and partner of Fomat, describes his company’s range of paper-making components, highlighting its focus on innovation, high-quality and energy efficiency. by: TissueMAG
Profitable Solutions For Paper Industry
omat is based near Lucca, northern Tuscany, where it was founded by Bruno Giannelli in 1973. It started as a commercial company, supplying quality service and innovative products to the renowned local paper industry. The company evolved very rapidly, starting to manufacture its own solutions and expanding its geographical markets. Today it serves customers over the world, supplying high quality and energy efficient products and complex systems to the paper industry. Fomat comprises four divisions: Technologies, Aerothermic, Automation and Handling. The Technologies division offers a wide product range, including felt and wire cleaning systems, water filters, basis weight control valves, monoflow and duoflow rotary joints, Yankee Doctor blade oscillators, edge cutters and tail cutters, and Yankee coating systems. The Aerothermic division takes care of complex systems dealing with air and steam handling. Its focus is on paper drying and creating a healthy paper mill environment. Its range of systems includes Yankee hoods, hall ventilation, Yankee head insulation, and dust and mist removal solutions, as well as steam systems for tissue machines. The Automation division is focused on paper mill management and process control, offering quality control and distributed control systems. Recently, the Handling division has been added, which allows Fomat to increase its product range with conveyors, expandable shafts, shaft pullers and the handling of the paper roll up to converting.
like no other
Wide variety of products for the tissue paper industry. From standard to customized systems taylored to customers’ needs
Innovation is a must “All our divisions are very important”, Bruno Giannelli remarks. “Our aim is that of providing optimal solutions for our customers’ needs. The solutions we provide to paper mills are always tailor-made, in order to fulfill this objective. Even the components that we provide to paper-making machine manufacturers are customised, according to the energy needs of the country in which their final customer is based. Energy efficiency, quality and ease of use are at the very heart of what we do”, states Giannelli. “For this reason, innovation is a must. This energy efficiency was possible thanks to our Integrex product, a heat exchanger and boiler.
uuCOMBO air system.
Profitable Solutions For Paper Industry
like no other
Knowledge and technological innovation for paper mills, with systems that guarantee reliability, production quality and energy savings
Basically, the burner only ignites to produce the small amount of steam that it is needed. The space saving result was possible through the use of a combo solution. As all its components are pre-assembled at our premises, this solution also minimises machine downtime during installation and future upgrades, as the necessary work can be carried out in only seven days.” The company operates from a sole site, comprising four buildings, with planning permission gained to build a further facility here. All production takes place at these premises, because the company has a vertical production model, internally taking care of all the necessary production processes, from raw steel to final product. No outsourcing or delocalisation strategies are employed. Geographically, the company supplies its solutions all over the world. “We have customers all over Europe, North and South America, Africa, the Middle East and Australia, as well as Japan and Korea”, says Giannelli. “We serve customers in every market that demands high-quality products. Our future is one of innovation. We have new cleaning systems for felt and wire. I expect significant demand for them, as they
▲▲Recovery Boiler INTEGREX.
offer better cleaning results, while lowering water consumption. We will also bring the market products and complex systems with increased energy efficiency, which I think will be successful, as I believe that reducing energy consumption will continue to be a vital factor for any manufacturing company.” ●
FOMAT SRL Via del Mulino 24 55015 Montecarlo (LU) - Italy ■ website: www.gruppofomat.com ■ phone: +39 0583 496040 ■ email: email@example.com
Pure performance is about constant development
■■ Tensile strength has been successfully improved, currently 10% higher than at start-up and will improve even further. Paul Wallstabe, Specialist Products (photo Torbjörn Bergkvist).
“We are focused on having the best pulp offer for Tissue on the market, to achieve this requires constant development and listen carefully to what our customers need. Of course, our ECF and TCF pulp must hold the highest possible standard when it comes to product and environmental performance. But we must also constantly improve and develop, in close cooperation with our customers”, says by: SCA Pulp Arvid Eriksson, Sales Director Tissue Pulp Global. The best NBSK offer within the tissue business SCA’s large forest holdings and state-of-the art mill enables SCA Pulp to maintain unique conditions, delivering unprecedented environmental performance. SCA is the largest private forest owner in Europe and 50% of the wood is sourced from the company’s own forests. The other part is sourced from trusted, long-term suppliers, in northern Sweden. SCA has created a strong and integrated value chain. An industrial ecosystem that maximizes value creation from the forest through renewable
■■ We not only deliver pulp with strong environmental performance. We are also fully self-sufficient in energy, and a major producer of green electricity in Sweden. Arvid Eriksson, Sales Director Tissue Pulp Global (photo Torbjörn Bergkvist).
Allow us to make a pure commitment to your business
products and a resource-efficient value chain. “The stable wood supply from well managed forests and the strong Nordic fibres, with low variation and low coarseness fibres that are treated gently throughout the process is one of the keys to deliver unique fiber strength. Perfect for tissue and naturally complying with FSC and PFCE”, says Arvid.
ttTo really be able to support our customers with relevant innovations we need to be very attentive, close and proactively listen to our customers. Jörgen Bergström, Development Manager. (photo Torbjörn Bergkvist).
▼▼SCA Pure is a pure commitment to the environment, and our customer’s bottom line. Produced in energy-efficient processes that use resources wisely, and sourced from our own forests. (photo Torbjörn Bergkvist).
completely unique products in progress”, Jörgen says. One example is the premium strong SCA Pure. This product has been evaluated by a key customer on a number of occasions and is now ready for launch. The result from the customers test runs show that less pulp is consumed (e.g. basis weight can be reduced), drying energy is lowered because less beating is needed, with cleaner back water systems and possibility to increased production. “One insight is that customer’s requirements can differ quite a bit, but new innovative pulp products are very interesting to many. We have therefore chosen to devote a great deal of development resources to chemically modify the fiber surfaces”, Jörgen says. Another interesting innovation is a new pulp offering high wet strength in tissue. The new product has recently been tested and evaluated in a pilot machine with a customer delivering very promising results. ●
Internal tissue experts and mill support An important part of SCA’s offer is service and support to its global customers, which requires local presence. One of the key people many customers are grateful to is Paul Wallstabe, a very experienced process engineer and tissue specialist. Paul’s mission is to support customers with knowledge throughout the production chain. “We are always quick to give feedback to our customers, we honor it. And we understand how urgent it often is”, Paul says. The requests from SCA’s customers can cover everything from back office, production, development, logistics and technical support. In addition to local presence, SCA has developed a support team that can quickly and efficiently help customers. “Pleasingly we get very positive feedback from the customers for the moment. Tensile strength and uniformity are good. We also hear that less drying energy is required from our customers. Feedback regarding runnability has only been positive, actually runnability is a lot better than our set targets”, says Paul proudly.
Pure innovation “We have always worked in close collaboration with our tissue customers to develop new unique properties and contribute to our customers business, it’s in our DNA”, says Jörgen Bergström, Development Manager at SCA Pulp. “SCA has a number of new, and
SCA PULP - ÖSTRAND PULP MILL Järnvägsgatan 2B SE 861 81 Timrå - Sweden ■ website: www.sca.com ■ phone: +46 70 2080797 ■ contact person: Arvid Eriksson, Sales Director Tissue Pulp Global ■ email: firstname.lastname@example.org
You might as well feed it your money.
How much is mechanical refining costing you in time, added pulp expense and energy use? Turn to MaximyzeÂŽ for tissue. It uses enzymatic technology to condition fibers without harming them.
ÂŠ 2019 Buckman Laboratories International, Inc. All rights reserved.
So you can maximize strength, save on pulp and energy costs and speed up production. Connect with your Buckman representative or visit buckman.com to learn more.
is always looking for the discovering of a better and improved product Azmec is projecting and producing machines that grant an excellent quality together with high performances even in very hard working conditions. It offers vacuum pumps of various dimensions to grant the customer a wide range of machines by: Azmec Srl working at different levels of energy consumptions.
he skill and the experience consolidated in 60 years of presence in the market (AZMEC was founded in 1960) say that AZMEC is a serious and available partner for all the companies of the paper mill industry that have to optimize the performances of its own vacuum plant, a main part of the paper machine. AZMEC is not only proposing its own solutions in new vacuum plants but allows the customers, through its overhauling service, to rebuild old pumps working since many years, to the original performances with an accurate revamping operation.
▼▼Vacuum pump group AL60 in AISI316L mechanical seal API681 execution.
AZMEC production includes six lines of vacuum pumps, machines available to grant capacities from 150 up to 50,000 m³/h. Together with the vacuum pumps, AZMEC offers to the customers all the available accessories, that’s to say the driving systems (pulleys and V-belts, gear reducers when the installed power is more than 355 Kw) the discharge separators, the silencers, the pre-separation groups, the safety valves, the self-priming extraction pumps and the dampers, just to mention the main parts. The vacuum pumps of the range AL/2000 cover a capacity interval from 150 to 12,500 m³/h; the range ALBV/2000 covers capacities from
2,000 to 7,500 m³/h and the characteristic of these pumps is to have practically two pumps in one due to the presence of a divider that creates two sections each one available to grant the 50% of the total capacity and different vacuum degrees. The same solution, but with horizontal suction nozzles, is granted from the pumps of the range ALZ/2000 that have the same range of capacities of the range AL/2000; with the size ALCZ, pumps available to work without and with the divider, the capacities reach the maximum of 50,000 m³/h; the range ALBC grants capacities from 450 up to 17,000 m³/h and the range ALB4 grants capacities from 4,500 up to 21,000 m³/h. A special care is offered from AZMEC to one of the problems that is present more and more frequently: the
reduction of the noise level of the machines according to the laws concerned to the ambient. To get the best solution, AZMEC offers to the customers the covering of the pumps with soundproof panels available to reduce the noise level to 75 dB(A); clearly these solutions can be applied also on machines already installed. The AZMEC proposal is not concerned only to the supply of its own machines; AZMEC is offering to the customers a complete service for the best arrangement of the vacuum plant. Usually AZMEC is preparing a lay-out of the
▲▲Vaccum pump group ALN75 mechanical seal + plan ATEX.
A leader company in the market, having in pole position the satisfaction of the customer 175
vacuum plant arranged according to space necessity and to customer installation just to optimize everything both from a technical view and a logistic view just not to have problems in case of maintenance. Just to go inside the maintenances, AZMEC overhauls not only its own machines but also the pumps of competitors. All the pumps are sent back with the due guarantee and with the test data available to confirm the right operating. To check the eventual necessity to arrange a maintenance, AZMEC can be present with its technicians near the customer workshop to do the measures of capacity, vacuum degree and absorbed power of the vacuum pumps present in the plant. Usually, AZMEC supply the customers with a spare pump so that the production has not to be stopped during the repairing of the pump.
We are always looking for the discovering of a better and improved product
▼▼Vacuum pump group ALC500Z with partial recirculation system of the service liquid.
It’s important to mention the last and very important supplies made recently from AZMEC: A2A GENCOGAS n.1 turn key solution skid AL75/2000 with soundproof cabin (Chivasso Plant Italy); FLSMIDTH MILANO n.3 vacuum skid AL40/2000 in AISI316 with soundproof cabin (final destination Spain); GAPCON TISSUE n.5 ALC420Z pumps + n.1 ALC400Z (final destination Indonesia and Bolivia); TECNIMONT SPA n.3 vacuum skid ALN64/2003 totally in AISI316 with double mechanical seals and API681 execution (final destination The Netherlands); ATLANTUM n.12 vacuum groups ALC420Z (final destination Belarus); ANDRITZ n.2 vacuum pumps ALC670Z and n.1 vacuum group ALC500Z (final destination Russia); FLSMIDTH MILANO n.2 vacuum skid ALN68/2000 direct coupling with double mechanical seal ATEX execution (final destination Indonesia); TECNIPLANT SPA n.1 vacuum skid ALC253Z with partial recirculation system of the service liquid + n.1 vacuum skid ALC500Z with partial recirculation system of the service liquid (final destination Germany). The production is arranged in two workshops: Arenzano (GE) and Verderio (LC). The vacuum pumps are manufactured through the use of CNC tool machines and tested in the certified test room. AZMEC is working according to the rules ISO 9001 and its target is to offer a more and more complete service to the customers, depending on the consolidated quality of its own products and on the efficiency of its staff. ●
AZMEC SRL Via Piave 79 23879 Verderio (LC) - Italy ■ website: www.azmec.it ■ contact person: Solange Cortellini, Business Unit Director ■ phone: +39 (0)39 514323 int. 3/4/5 ■ email: email@example.com ■ skype: solange.azmec
Tissue News, forecasts and market analysis
A trusted partner for professionals throughout the global tissue supply chain: Corporate strategy Sales & marketing Buying & trading Mill engineering and procurement Research & development Capital investment Resource allocation
Bolzoni Auramo partner in AGV applications
ttBolzoni Auramo AGV equipment.
Automation solutions applied to the material handling world are continuously evolving. Automated Guided Vehicles are included in this change and represent the new challenge for forklift truck and attachment manufacturers today. by: Bolzoni SpA
s strategic choice to support facilities implementing the Industry 4.0 philosophy, AGV solutions integrally fit in this project mainframe and can become a key tool to develop innovative processes. In strict cooperation with main AGVs producers, Bolzoni Auramo has developed a range of attachments
equipped with specific sensors controlled and managed directly by the AGV control unit. The latest technology development in Bolzoni has been to design and manufacture fully electric driven attachments. The possibility to avoid any hydraulic has multiple benefits: cleaner environment, better and more efficient connection with the AGV control system, more precise,
reliable and repetitive movement and correct positioning of the different attachment operations. Bolzoni is investing heavily in electronic technology, using more and more sensors and cameras. In paper world, specifically in tissue paper production facilities, significant heavy machines and important clamping force, necessary to handle big rolls, steer the technical decision to
ttBolzoni Auramo AGV equipment.
more traditional hydraulic solutions. A worldwide leader in tissue production and distribution for one of the biggest plant in North America, decided to manage transportation and warehousing of parent rolls (more than 5 tons/11,000 Lbs of weight and 3 meter/118â&#x20AC;&#x2122;â&#x20AC;&#x2122; of diameter) with heavy LGVs equipped with Bolzoni Auramo dedicated clamps. The hydraulic system and the sensors set
have been co-designed with the LGV manufacturer and specifically adjusted to marry the control system of the automatic machine. When the AGV needs to position the forks for different pallet sizes, it can use a Bolzoni Auramo electric driven fork positioners, operated by electric actuators, easy to control and more precise in positioning. Same if the need is to rotate a bin. The electric driven
rotating device can do the work in a much better, clean and easy way. So when an important AGV producer had to face the mission for a worldwide tobacco producer to clamp, stack and empty by rotating bins of tobacco, they decided to cooperate with Bolzoni Auramo and to co-design fully electric driven 360-degree rotating box clamps. Same concept for one of the leader producers in food and
▼▼Engineered for the Tissue paper industry, the Bolzoni Auramo roll clamp.
▲▲Fully electric driven 360-degree rotating box clamp.
As well, in collaboration with another world leader in AGV and automatic solution provider, Bolzoni Auramo developed fully electric fork positioners for the automotive industry. The units, thanks to electric actuator, are able to precisely position the forks depending on the load to carry. A full set of sensors installed on the attachments help the AGV to exploit the different missions and to fulfil all handling needs in the manufacturing
Company’s values are the inner beliefs of our business and the basis of our behaviors beverage industry operating worldwide using narrow aisle AGVs equipped with electric driven Bolzoni Auramo trilateral head. Beyond the possibility to avoid hydraulic fluid in the handling equipment, the AGV manufacturer has been able to better control the unit, allowing complete 180-degree rotation of the head inside the aisle, great advantage to increase the speed of the operation, therefore the productivity of the warehousing system.
and independent dealers covering all continents it is able to satisfy all market requirements. Through the Bolzoni Auramo and Meyer brands, the Group offers the most extensive product range in the market. Bolzoni Auramo and Meyer serve material handling industries in the areas of forest products, white goods, logistics, food and beverage, chemistry, steel, automotive and many others. Robust products, with superior visibility, handle loads efficiently, safely and damage free. The Bolzoni Group is totally committed to continuous quality improvements, providing excellence to customers worldwide. ●
and warehousing processes. To offer the best tools for improving customer processes, AGV solution providers can rely on the cooperation with Bolzoni Auramo. Bolzoni is one of the worldwide leading manufacturers of lift truck attachments, forks and lift tables. The company has manufacturing plants in Italy, Germany, Finland, America and China and through its network of direct branches
BOLZONI AURAMO Via I Maggio 103 29027 Casoni di Podenzano (PC) - Italy ■ website: www.bolzonigroup.com ■ contact person: Lars Petersson ■ email: firstname.lastname@example.org
▲▲Bolzoni Auramo trilateral head for narrow aisle AGV.
Two specialists, no compromise! New 5 MWe Gas Turbine developments and Efficiency by: KAWASAKI Gas Turbine Europe GmbH World-Record Gas Engine.
he M5A-01 (4.7 MWe) is the latest model and a new member of the family of Kawasaki Gas Turbines. The reason for the development of this 5 MWe class Gas Turbine was to close the gap between the M1 (1.8 MWe) and the M7 (7.8 MWe) family and not at least to meet the changing requirements of the market. The development focused on outstanding performance in terms of efficiency, usable exhaust heat and the compactness of the Gas Turbine. The experience gained from the proven technologies of the M1- and M7-families was a decisive factor in the development. The result is a compact and reliable single-shaft industrial Gas Turbine especially for smaller combined heat and power (CHP) applications where a maximum of electrical efficiency
â&#x2013; â&#x2013; Gas Engine.
and at the same time maximum usable waste heat is required. The M5A-01, or GPB50D as a completely assembled package, has the highest electrical efficiency in its class - coupled with a correspondingly high exhaust gas temperature for steam generation, a very high overall efficiency is achieved. A strong contribution in terms of profitability and environmental friendliness. The electrical efficiency of this Gas Turbine is 33% and emissions can be reduced to <15 ppm for NOX by the proven Kawasaki Dry Low Emission (DLE) technology and for CO < 25 ppm from 50% to 100% load. Here again 6 DLE combustion chambers, a proven fuel system and a simple housing design are used. Other big advantages are longer and customer-friendly maintenance intervals. The compact and very light Gas Turbine (Power Section)
KGE provides a complete and comprehensive range of products and services from one single source
â&#x2013; â&#x2013; Gas Engine.
■■ M5 Gas Turbine.
▲▲M5 Gas Turbine.
can be easily and quickly replaced, thus reducing downtime. All in all, not a simple gap filler, but a full-grown specialist in its class.
We will use our integrated technological expertise to create values that point the way to the future
Efficiency World-Record Gas Engine
The development of the Kawasaki Gas Engine series is based on 100 years of experience in the construction of diesel engines. They have been developed since 2007 using new computer-based design, flow simulation and strength-calculation programs. These Gas Engines are used for stationary generation of electricity, but for peak-load-controlling, primarily used as combined heat and power plants. Due to the high electrical efficiency of the Kawasaki Gas Engine family, highly efficient electricity is generated. The waste heat from exhaust gas and cooling water can be treated as process heat or e.g. used as thermal heat. The engine range includes the four models KG-12, KG-12-V (5.2 MWe), KG-18 and KG-18-V (7.8 MWe). The number indicates the number of cylinders, which are arranged V-shaped in two cylinder banks, the V in the model designation, however, characterizes the turbocharger (variable nozzle) with increased efficiency. As the flagship of the Kawasaki Gas Engine range, the KG-18-V achieves the highest electrical efficiency in its class, with 49.5% at the generator terminal. Noteworthy here is its large control range of 30% to 100% of the electrical output power and that he achieved a very high efficiency even at partial load. Already over 143 of these engines were sold in Southeast Asia and the USA. In Europe, Kawasaki engines have been available in the market since the beginning of 2017.
While the use of photovoltaic and wind power plants is establishing itself for the CO2 neutral generation of electricity, the regenerative provision of high-temperature heat for industrial processes has been somewhat behind. As a solution, for example, the use of pure hydrogen in Gas Turbines and the flexible switching between the natural gas and hydrogen fuels have been further developed. This is done in close cooperation with European research institutions such as RWTH Aachen University. Three processes were examined in more detail: the fully flexible switching of the natural gas and hydrogen fuels in the Gas Turbine’s diffusion combustion chamber, the addition of hydrogen to the Gas Turbine’s DLE combustion chamber with approx. 30% of the calorific value and the Micro-Mix combustion chamber, especially designed for hydrogen combustion. Those compromising developments will be ready for the market in 2020. ●
KAWASAKI GAS TURBINE EUROPE GMBH Nehringstr. 15 61352 Bad Homburg - Germany ■ website: www.kawasaki-gasturbine.de ■ phone : +49 6172 73630 ■ email: email@example.com ■ contact person: Shahrad Adjili, Sales Manager ■ email: firstname.lastname@example.org
Tissue news around the world Gambini delivers its first Japanese TouchMax
Gold HongYe Paper (Hubei) purchases three new Tissue A.Celli E-WIND® T-200S Rewinders
he recently established partnership between Gambini SpA and Kawanoe Zoki Co., Ltd., the Japanese industry leader in tissue-converting machinery, has already led to great results: for the first time a Japanese tissue producer has chosen Gambini’s TouchMax technology for its embossing needs. Fuji Satowa was founded in 1922 and is now located in Fuji city, Shizuoka prefecture, at the center of Japanese paper industry. They mainly produce toilet paper, using recycled pulp such as pre- and post-consumer waste material. TouchMax is a patented technology embosser providing extraordinary flexibility during product changeover, thus multiplying the marketing opportunities related to different embossing patterns.
he APP Group management signed the purchase order for three A.Celli E-WIND® T200S (shaftless) tissue rewinders for Gold Hongye Paper factory in Xiaogan, in Hubei province, China. Two of the three rewinders are equipped with four unwinders, while the third has three; they will all handle mother rolls with diameter of 3,000 mm and paper width of 5,630 mm, having basis weights varying from 10.5 to 45 gsm, and with a maximum operating speed of 1,100 mpm.
First orders for Together from Futura
matter of weeks after introducing the revolutionary Together technology at the MIAC event in Italy, Futura has received the first two orders for Together converting and packaging lines, a solution born out of Futura’s technical partnership with Plusline announced in October 2019. The clients remain confidential and start-up is due at the end of 2020. Futura’s technical partnership with Plusline was conceived with the aim of introducing radical innovations, the first of which is Together, a game-changing solution to convert logs into shelf-ready packs. Together is an integrated system which can be installed downstream of any existing or new converting rewinder line, not necessarily produced by Futura, thus opening opportunities both for setting up new plants, and for making existing lines much more efficient.
Toscotec-supplied tissue line comes online at Picknik Marketing, South Africa
outh African tissue manufacturer Picknik Marketing Pty Ltd started up a MODULO-PLUS tissue machine supplied by Toscotec at its Johannesburg mill. The new line produced high quality tissue from day one. The MODULO-PLUS machine has a sheet width of 2,750 mm, an operating speed of 1,500 m/min, and a production capacity of 75 t/d. It features a second-generation TT SYD Steel Yankee Dryer and energy-efficient, gas-fired TT Hood. The supply also includes the stock preparation and approach flow equipment and an off-line shaft puller. The service package includes erection supervision, commissioning, start-up assistance and training.
MACHINERY AND PLANTS FOR THE PRODUCTION OF PAPER AND PAPERBOARD AND FOR THE CONVERTING OF TISSUE PAPER
14.15.16 OCTOBER 2020 LUCCA - I TALY
Edipap Srl www.edipap.com email@example.com
TOSCOTEC AHEAD LINE PERFORMANCE BY TOSCOTEC
Speed is not an option and when joined by leading-edge technology, evolved engineering and the highest levels of performance, it becomes a must. Toscotec allows you to reach this goal with its AHEAD Line: the high-speed tissue machine range capable of attaining 2,200 mpm and producing high-quality tissue from virgin and recycled fiber with proven energy savings, maximum efficiency and reliability. The performances your business was just waiting for. YOUR NEEDS, OUR SOLUTIONS.