TWMilan Technical Abstracts (v6)

Conference Abstracts

TECHNICAL SESSIONS 1 to 3 - 11 APRIL 2017 Technical Session 1 - Industry 4.0 : Computerisation of Smart Manufacturing for the Future of Today

Introducing an auto-adaptive process control system that almost no one wanted Wes McConnell, CEO, Frameworxs Analytics, USA 12:40 – 13:00 The speaker introduces DaVinxi, a cloud-based, auto-adaptive process control strategy designed to allow tissue machines to produce consistent quality at the lowest cost, even under varying operating environments. Results can also be combined with quality and financial data to create actionable information.

The author explains how this technical approach works, discusses the difficulties of implementing the system and how the team overcame these challenges.

Finally, the author describes why almost no-one wanted this technology. However, over time, they all wanted it.

DaVinxi is now in its next level of development

Industry 4.0 for direct data exchange between production, converting and consumer Giovacchino Giurlani, Head of Technology and FuturaLab, Futura , Italy 13:00 – 13:20 Industry 4.0 is about big data analysis and the way this information is communicated. What has this got to do with tissue converting? Until now, not so much.

But change is here and Futura will explain how the important data which can be generated during tissue manufacturing can now be transmitted direct to the converting facility and vice-versa. It means that the converting line can respond automatically to the characteristics of the tissue paper which it processes.

The tissue converting line can, in turn, report to downstream processes right to the point where the consumer picks the product off the shelf.

Industry 4.0 seems like a big idea but in reality it is about the collective power of many small changes to affect significant improvements in Overall Equipment Effectiveness. Its impacts can be felt in terms of product quality, production efficiency, safety, maintenance routines – the list goes on.

Futura presents actual examples of converting technologies developed at FuturaLab to make better use of data analysis. Futura will explain how the process of building intelligence into converting will have real-world effects: better process control, preventing avoidable stoppages and improving traceability, all with target of keeping the line running at best efficiency. It will enable tissue manufacturers to realise their Industry 4.0 ambitions – a goal already being realised in advanced tissue converting facilities.

Conference Abstracts

TECHNICAL SESSIONS 1 to 3 - 11 APRIL 2017 Technical Session 1 - Industry 4.0 : Computerisation of Smart Manufacturing for the Future of Today

Working with Industry 4.0 in tissue packaging: a rewarding challenge Martina Stefanon, Business Development Director for Services Innovation, TMC, Italy 13:20 – 13:40 Industry 4.0 and its related technology will have a growing impact on production processes from now on. Exploring it is challenging but extremely rewarding. TMC will introduce operational results it has obtained. The power and the value of data increase when shared.

TMC presents an application of industrial IOT and analytics on packaging machines in the tissue industry.

Connecting machines to provide contextual insights in real time and approaching asset management in a completely new way brought cost savings, higher quality, higher production efficiency, and expected longer asset life. TMC has developed and tested the technology on machines in a real production environment in the following applications: 1. Proactive monitoring of OEE and machine health status 2. Online diagnostics and troubleshooting 3. Proactive monitoring and analysis of all variables, parameters and KPIs involved in production processes. Automatic alerts and fault analysis.

4. Condition based and predictive maintenance Field application results will be discussed focusing on benefits for Tissue manufacturing companies.

Improving safety, quality, service to customers and profitability through integration & automation William A. Nelson, President, Elettric 80 Inc & Eletric 80 S de RL, USA 13:40 – 14:00 Elettric 80 will present the safety, quality and profitability improvements derived by maximizing integration and automation into the design of tissue production facilities. We will show how maximizing integration and automation throughout the tissue production facility and value chain helps optimize processes, product quality, and ROI. In particular, it promotes safety by reducing the need for people and eliminating fork lifts in the production area. It enhances product quality and reduces the risk of damage in storage and shipping. It improves customer service through increased precision, punctuality and traceability of deliveries.

This all leads to higher profit because of decreased waste, raw material savings, reductions in personnel and related work interruptions and higher productivity. Less covered building space is needed and a series of savings are made possible through the adoption of modern technology.

Conference Abstracts

TECHNICAL SESSIONS 1 to 3 - 11 APRIL 2017 Technical Session 1 - Industry 4.0 : Computerisation of Smart Manufacturing for the Future of Today

Comprehensive remote support

Francesco Maltagliati, Chief Customer Service Officer, Fabio Perini, Italy 14:00 – 14:20 Today we are on the verge of a deep change, characterized by process transformation and by Industry 4.0, a revolution of intelligent systems where machines, products and people are inter-connected.

The right equipment must be backed with the expertise and speed of response of a team that can offer a genuinely comprehensive support service.

Dealing with technical service inside countries difficult to reach, training junior technicians in order to operate correctly and efficiently with the technology and process, managing in the meantime both converting and packaging equipment, as well as electrical and mechanical issues, are all examples of how this innovative device can simplify day by day activities, improve efficiency and growth.

This is what the Tissue industry is experiencing nowadays thanks to WeAreAble, the video, data, and audio-voice helmet that enhances the remote service support as never before.

Above all, one of the first interventions on a converting line for a customer with a lack in machinery know-how: the replacement of a drive and an engine tuning, using the helmet through the guide of an experienced technician based in the Fabio Perini Technical Center.

Conference Abstracts

TECHNICAL SESSIONS 1 to 3 - 11 APRIL 2017 Technical Session 2 - Raw Materials and Fibres - Properties, Morphology and Sustainability

Influence of pulp mixture and process parameters on strength properties of low grammage laboratory sheet Mattias Drotz, Business Development Papermaking and Packaging, RISE Bioeconomy, Sweden 14:40 – 15:00 For tissue, strength, absorbency, and haptic properties are important. Tissue makers strive to retain strength without sacrificing haptic properties or absorption. Sufficient strength is required not only to satisfy the consumer’s needs, but also for efficient production both on the tissue machine and in the converting line, for example to withstand out-of-plane deformation during embossing.

The scope of this study was to investigate strength properties at lower grammages. Mixtures of different chemical pulps worldwide were selected. Handsheets of a range of grammages were manufactured under different wet pressing and refining conditions. After drying the handsheets, their mechanical properties were evaluated. Standard methods were used for the mechanical properties, e.g. tensile test and ball-burst strength.

Furthermore, a thermography-based method for the local in-plane deformation and stress distribution of tissue products was used to record the surface temperature distribution of the tissue samples during straining. The local variations in temperature were interpreted as plastic deformation due to the dissipation of energy.

The role of softwood fibre morphology in runnability of a toilet tissue line Tuomo Niemi, Technical Sales Manager, Metsä Fibre GmbH, Germany 15:00 – 15:20 A softwood comparison study was conducted on a pilot tissue machine. The goal was to see if different softwood fibre morphology and chemistry (fibre length and coarseness or hemicellulose content) would affect the runnability of a tissue machine or converting line. Raw paper was produced using a typical toilet tissue furnish with high eucalyptus content to constant tensile and stretch targets. Converting to the final toilet tissue product was conducted using standard conditions.

The results suggest that high softwood and hemicellulose content give a higher performance profile in the tissue paper. High hemicellulose content combined with high fibre number contributes to process advantages such as low refining energy to constant tensile, good formation and lower drying energy. In the converting line the papers behaved differently. The higher fibre number of softwood contributes to lower loss in MD strength during converting.

The trials also tested of two different adhesion packages. The results show that using a constant furnish the differences can be seen in TSA-softness parameters.

Conference Abstracts

TECHNICAL SESSIONS 1 to 3 - 11 APRIL 2017 Technical Session 2: Raw Materials and Fibres - Properties, Morphology and Sustainability

Pulping non-wood fibers with lower water, energy and chemical input Mark Lewis, President, Sustainable Fiber Technologies, USA 15:20 – 15:40 As more tissue companies explore the use of alternative fibers, there is the potential for a wide use of biomass. This paper shows the refiner curves of a number of nonwood fiber sources as well as photomicrographs taken of these pulps. The Phoenix process is an environmentally friendly process that uses only 15% as much water as a kraft mill, while needing significantly less energy and chemical input.

Getting out of the commodity market - high tensile eucalyptus grade Bibiana Rubini, Product Development Coordinator, Fibria, Brazil Dr Pierre Noé, Managing Partner, CP-Partners, Switzerland 15:40 – 16:00 The different eucalyptus market pulp grades offer little differentiation between themselves and are rightly considered interchangeable. The development of a ‘high tensile’ eucalyptus grade custom designed for applications in tissue has allowed Fibria to step out of this commodity market for part of its products, while answering market demand at the same time. The incorporation of a biopolymer in the course of the pulp making process has allowed to reach a pulp tensile increase by 30% while preserving the bulk and softness of the product – hence the name of EucaStrong.

The project started in 2006 and evolved from lab scale to industrial scale. Over 20 industrial trials were conducted in cooperation with Fibria’s customers. A wide variety of tissue making technologies were covered as well as all tissue segments.

Successful applications with benefits on quality and costs will be presented during the conference.

Conference Abstracts

TECHNICAL SESSIONS 1 to 3 - 11 APRIL 2017 Technical Session 2: Raw Materials and Fibres - Properties, Morphology and Sustainability

Good manufacturing practice: more than a legal requirement, a competitive tool Eugenio Cavallini, Consultant, Ecol Studio S.p.A., Italy 16:00 – 16:20 In the European Union and since 2008, the implementation of a GMP system has been a legal requirement for companies that produce materials for food contact applications. Even without the legal aspect, working in a GMP environment may present the opportunity for companies to improve their general processes, even if they are not directly involved in the food contact sector.

This is because GMP is based on in the principles of Quality Management Systems, which makes it easy to implement in companies that are already certified according to ISO 9001 standard.

The self-regulating approach typical of GMP is expected to be one of the key points of the evolution of the legislation at EU level: the main European associations of the P&B supply chain are working on a harmonised measure based on such an approach.

Since tissue products are at the borderline between food contact and non-food contact use, implementation of a GMP system can help in approaching the market even when a company has chosen not to apply the food contact legislation to their products.

Conference Abstracts

TECHNICAL SESSIONS 1 to 3 - 11 APRIL 2017 Technical Session 3: Chemicals - Improved profitability, strength and softness

Wet strength resins to provide economic and environmental benefits

Dr. Vladimir Grigoriev, Manager, Business Application Development, Wet end, Paper, EMEA, Kemira Chemicals Germany GmbH, Germany 16:20 – 16:40 Wet strength in tissue and towel products is traditionally achieved by using relatively high dosages of a wet strength resin (WSR). This puts a substantial pressure on the tissuemaker’s profitability both due to high chemical cost and due to negative effects from WSR on machine runability such as foaming, felt deposits and reduced dewatering. In recent years, tissuemakers have also been under pressure to reduce the AOX levels in their effluent, to which WSR can be a significant contributor. Thus, there is an acute need for economically effective solutions for reducing the WSR consumption.

Kemira has developed innovative chemical solutions to provide economic and environmental advantages in the production of wet-strengthened paper grades. Among them are high efficiency FennoStrength resins that generate target wet tensile at a 5-25% lower dosage compared to the market resins. Furthermore, WSR can be complemented by novel synthetic functional promoters, e.g. anionic FennoBond or cationic FennoBond, to improve the WSR efficiency even further. Reduction in the WSR consumption leads to an AOX reduction in effluent and paper. Additional benefits from using functional promoters are increased dry tensile and improved machine runability. In this paper, we will present on these concepts and demonstrate their benefits using industrial case studies.

Authors: Vladimir Grigoriev, Christophe Woelfli, Jean-Philippe Berger and Alexander Kuzinsky

How to boost dry strength in tissue and towel but still keep softness

Angela Knight, Platform Launch Manager Business Application Development Wet end Paper EMEA, SOLENIS, UK 16:40 – 17:00 Wet-end dry strength additives, such as polymeric agents and enzymes (refiner aids), use various mechanisms to generate strength in a tissue system, depending on furnish type. The resulting increase in dry strength can be used by the tissue maker in various ways to achieve cost savings in terms of fibre cost (replacement), energy reduction and decreased basis weight.

The use of all types of dry strength additives has increased in recent times but in some cases negative side effects have been observed, one of which is a loss of sheet softness or a creation of stiffness due to various influences. The challenge has been to create dry strength additives that generate the desired increases in dry strength without impacting other critical value providing sheet properties such as softness. This paper highlights, through the use of numerous recent case studies, the added value that a new and novel dry strength agent can bring to the tissue maker without impacting softness and other sheet properties.

Conference Abstracts

TECHNICAL SESSIONS 1 to 3 - 11 APRIL 2017 Technical Session 3: Chemicals - Improved profitability, strength and softness

Cost effective surface treatments for softer tissue

Mark S. Christopher, Manager Marketing Communications Buckman Europe, Middle East, N. Africa, Buckman International, USA

17:00 – 17:20 Traditional softness additives for improved surface feel have been largely focused on wet end debonding chemistries and converting applied lotions. Developments in tactile improvement additives over the past few years has resulted in a new class of chemistries that can be applied on machine without the detrimental tensile impact of debonders or the high cost and application complexity of converting lotions.

Transfer Efficiency study of spray systems in high web speed additives Benjamin H. Drummond, Senior Engineer Paper Market, Spraying Systems, Canada 17:20 – 17:40 Many applications in the paper industry use webs at speeds of 1,500 m/min and higher, which creates an air barrier near the web surface. If liquid needs to be applied, this air barrier can prevent it reaching the web, a loss leading to wasted chemicals, environmental safety hazards, and added maintenance or cleaning.

This work investigates the parameters that influence transfer efficiency. An experimental design approach was employed to measure and validate critical parameters of the spray system. Application rate, pressures, header distance, and web speed were altered to quantify the effect on transfer efficiency. A combination of particle image velocimetry (PIV), laser induced fluorescence (LIF), phase Doppler interferometry (PDI), and weight analysis was performed under controlled laboratory conditions. A low speed web was replicated in the lab for model validation.

Transfer efficiency was predicted using computational fluid dynamics (CFD) simulations and empirical data from laboratory studies, as it related to spray technology. The computational model and simulations were conducted using the ANSYS Fluent modeling software package in conjunction with methods developed at Spraying Systems Co. The computational model’s agreement, and disagreement, with the experimentally acquired results provides insight for optimizing transfer efficiency in high web speed applications.

Conference Abstracts

TECHNICAL SESSIONS 1 to 3 - 11 APRIL 2017 Technical Session 3: Chemicals - Improved profitability, strength and softness

Carbon Dioxide based Applications for Process Optimization Ann-Charlotte ‘Lotta’ Jansson, Expert Pulp & Paper, Linde AG, Germany 17:40 – 16:00 Stable and correct pH is a prerequisite for good runnability and for optimization of the wet end. Too high pH is easily corrected with carbon dioxide as long as the target pH is not too acidic. Carbon dioxide forms a weak acid when it reacts with water. This makes pH control with CO2 much more stable than when using strong acids. When carbon dioxide is used, no problematic ions are added to the process.

At mills where recycled fibers are used, some calcium carbonate may enter the wet end process with the raw material and can cause problems if some of it dissolves. Dissolution of calcium carbonate not only increases process water hardness, but can also cause formation of big carbon dioxide bubbles that are difficult to dissolve. This increases the amount of “entrained air” and can cause foaming.

It may sound strange, but using carbon dioxide based applications can actually prevent formation of big carbon dioxide bubbles.

Market pulps tend to be more or less acidic. As a result the wet end pH can be too low and it can also be varying with pulp composition and amount of broke.

Both pH variations and increased process water hardness affect the efficiency of many chemicals and can cause problems with spots and deposits.

Linde has developed several carbon dioxide based applications for the pulp and paper industry. Some of these applications are ACTICO® active control and ADALKA® process stabilizer. These applications can be used to stabilize and control pH (both increase and decrease) and to prevent dissolution of calcium carbonate. The applications can be looked upon as a toolbox for process optimization.

Depending on the process conditions, suitable tools are chosen and applied in a tailor-made way. This paper will explain how these applications work and give some examples of how they have been used in mills using virgin pulp as well as recycled pulp.

Conference Abstracts

TECHNICAL SESSIONS 4 to 6 - 12 APRIL 2017 Technical Session 4: Improvements and Innovations - Efficiency enhancing and energy saving technologies

Recovery steam generator system gives energy savings at WEPA Lille Adriano Lazzini, General Manager, PMPOWER SRL, Italy Speaker to be named, Mill Manager, WEPA Lille, France 09:00 – 09:20 In February 2016, WEPA Group ordered a PMPower recovery steam generator system for its Lille mill in France. The project started up five months later.

The driving force was modern technology that ensured energy savings solutions, including a recovery steam generator system running off the hood exhaust fumes. The new system allows steam generation of 1.2 tph and guarantees a high level of flexibility. It saves more than 25 % of steam flow from the main generator to the machine and as a result fuel consumption is reduced as well. To sum up: a blend of state-of-the-art technology and flexibility of execution has brought the expected results.

The next level of environmental friendly tissue production

Bernhard Kohl, Vice President Project Sales, Voith Paper Rolls GmbH & Co. KG, Germany Magnus Bengtsson, Development Manager Corporate Development, Duni AB, Sweden Jan Achtermann, Global Grade Owner Tissue, Voith Paper, Germany 09:20 – 09:40 Tissue products for daily uses have to provide not only functionality but also a good feeling when buying and using it. Of course, tissue needs excellent absorbency, strength and bulk, but also has to be environmental friendly.

Since 2014, Voith Paper and Duni have worked closely together to adapt the TissueLev application in tableware as a new technology for environmentally friendly tissue production. The aim is to develop a new standard for tissue napkins with reduced environmental footprint. Several series of trials at the Voith pilot facility in Sao Paulo have been made to develop, prove and fine tune the technology. In April 2016, PM1 in Bengtsfors was equipped with TissueLev technology. This is the first installation for continuous operation worldwide.

One month later PM2 was converted. Duni and Voith have worked together using the new technology to support Duni’s objective of supplying GOODFOODMOOD with a reduced environmental footprint with no loss of quality.

A long term co-operation agreement has been made to develop quality and productivity while cutting operating cost. A working group was nominated with experts from both parties in production, technology as well as clothing which secured a quick start-up and development of the TissueLev application.

Conference Abstracts

TECHNICAL SESSIONS 4 to 6 - 12 APRIL 2017 Technical Session 4: Improvements and Innovations - Efficiency enhancing and energy saving technologies

A new perspective on cogeneration towards a higher energy efficiency

Paolo DellaNegra, Manager of Sales Department, Valmet Benoît Fécamp, Global Tissue Market Development Manager, Solar Turbines Power Generation, Switzerland 09:40 – 10:00 Cogeneration, the combined production of electrical and thermal energy obtained by the same primary source, has become a well-established technology in tissue production.

Of the Tissue machine heat needs, only the steam production is typically covered by the cogeneration.

The real game changer in energy efficiency comes from the utilization of the gas turbine exhaust gases directly for tissue drying. The gas turbine exhaust flue gases, naturally clean and odourless, can be directly conveyed to the drying process of either conventional, textured or structured products. Thanks to the typical heat to power ratio of the gas turbines which matches the tissue machine’s, the cogeneration fulfils both the thermal and electrical needs of the tissue production. The energy efficiency of the global system is increased and energy costs are drastically reduced.

In the light of the above, Valmet and Solar Turbines (and its subsidiary Turbomach) have been forming a cooperation agreement in 2016 to further develop their common activities in the integrated cogeneration field applied to the tissue production process.

Their strength resides in the experience acquired over time and in the deep knowledge of both processes - tissue production and drying, and cogeneration. The innovative concept of “tailor-made” cogeneration that covers most of a tissue machine energy requirements, as well as a successful case history, will be presented.

Conference Abstracts

TECHNICAL SESSIONS 4 to 6 - 12 APRIL 2017 Technical Session 4: Improvements and Innovations - Efficiency enhancing and energy saving technologies

A fresh perspective on tissue production

Thomas Scherb, Director Tissue South America, ANDRITZ AG, Austria 10:00 – 10:20 Over the past couple of years the tissue business has been characterized by severe competition and cost pressure. Tissue producers face several challenges and the key factors for tissue production – high quality demand and efficient, energy-saving production – seem to be in contradiction.

Mission impossible? Not any longer.

One of the latest ANDRITZ orders, the delivery of a worldwide unique tissue production line to Carta Fabril in Brazil, highlights new energy saving possibilities in tissue production. The new PrimeLineST W22 machine features – with 5.5 m width and 2,100 m/min speed – the world’s largest steel Yankee for tissue. This giant, made of steel, has a diameter of 22 ft. and, in combination with a steam-heated hood, enables efficient drying with substantial energy savings and safe operation. The thermal drying process will use 100% renewable energy generated from biomass and converted into steam.

Beside this world-record machine, ANDRITZ is introducing a concept for increased wet-end dewatering on conventional tissue machines, resulting in higher dryness before and after the press, as well as solutions for reduced thermal drying energy.

Shoe press technology: how to improve product quality and operating cost Stefano Marenco, R&D Director, Toscotec Spa, Italy 10:20 – 10:40 What determines the type of pressing system to install on a tissue machine?

The precise control of the multiple zones of the TT NextPress shoe allows flexibility in operation to achieve high quality production and machine runnability. The shoe pressure tilt control allows flexibility in producing bulky paper or saving energy through higher post-press dryness, while different edge pressures generate local loading curves that eliminate problems such as edge stilling or extra dry paper.

In the paper the author will highlight the main advantages of this new TT NextPress technology validated by field data from the recent start-up of these applications.

Conference Abstracts

TECHNICAL SESSIONS 4 to 6 - 12 APRIL 2017 Technical Session 5: Converting technologies, maintenance, spray and lotions

Simple Crescent former machine: Papergroup case study Rony Michelini, Sales Application Engineer, Recard, Italy Claudio Bianucci, Plant Manager, Papergroup, Italy 11:00 - 11:20 The Easy Crescent plant is entirely installed at ground level and requires easy civil works. The plant can be equipped with an efficient stock preparation line, a simple and smart approach flow system and the paper machine has only one blind drill press roll. It can be equipped with several energy saving solutions.

This plant is designed for companies entering tissue production for the first time, for those who have already an available building and also for those who intend to produce medium-high basis weights.

The Easy Crescent concept’s main features are space saving, simple civil works and erection, low energy consumption, simple maintenance and user-friendly operations.

We present the Easy Crescent technology and a standard Crescent Former and present and show the results of a real installation: the case of Papergroup.

Energy savings from advances in tissue suction pressure roll venting

Glen A. Harvey, Global Director of Value Results Engineering, Xerium Technologies, USA 11:20 – 11:40 The suction pressure roll is the main dewatering element in tissue manufacturing. Developments in roll cover materials and press felt technologies have made it possible to use advanced techniques in roll cover venting that deliver unprecedented water removal and energy savings. Conservative approaches to venting have been used due to the critical nature of the suction pressure roll nip (high speeds, relatively high loads, soft roll covers, and mating the roll against the Yankee dryer).

Sophisticated algorithms can calculate the amount of water present in the nip and the available void volume. Through the proper use of suction through holes, double drilled suction holes, efficient blind drilling, and specially designed grooves, the components can be engineered to provide sufficient void volume in the suction roll nip. The benefits include increased water removal resulting in energy savings or increased production. Cross machine moisture profiles are also improved.

This presentation addresses the need for excess void volume, the amount required, and the need for open area in the suction pressure roll cover. The most effective suction pressure roll venting patterns will be presented, as well as case histories illustrating their efficiency.

Authors: Glen A. Harvey, Charles Hunter, Steven Pearson

Conference Abstracts

TECHNICAL SESSIONS 4 to 6 - 12 APRIL 2017 Technical Session 5: Converting technologies, maintenance, spray and lotions

Increasing boiler efficiency with condensing heat recovery Robert Williams, Director, Energy Optimised Ltd, Europe 11:40 – 12:00 The condensing heat recovery technology is a specialized heat recovery unit that will increase the overall efficiency of the generation plant whether that is a standard steam boiler or combined cycle gas turbine.

As well as explaining the function of the technology the presentation will explain how it is applied particularly in the context that no two tissue mills are alike. The successful implementation requires and understanding of the total site energy use to best optimize the heat recovery potential.

The presentation will provide examples of how the technology was successfully implemented in a number of tissue mills and provide some case studies.

Maintenance engineering vibration damping of paper rewinder Bruno Celestino Fabiano, Development Engineer, Engefaz Group, Brazil 12:00 – 12:20 The rewinder at Suzano Pulp and Paper had shown vibration problems in its main beam for years, generating defective rolls and leading to excessive downtime. It also, for various reasons, operated at well below nominal operating speed and suffered from other faults.

To fix the vibration in the machine, Engefaz developed three distinct damping systems, operating at different degrees to the beam. These systems have performed well and the overall vibration has decreased substantially, eliminating a bottleneck that had lasted more than 10 years.

Conference Abstracts

TECHNICAL SESSIONS 4 to 6 - 12 APRIL 2017 Technical Session 5: Converting technologies, maintenance, spray and lotions

Concrete benefits on flying splice technology in a converting line: Goma-Camps case study Enrico Ruglioni, Business Development Director Tissue Europe, Spain 12:20 – 12:40 Converting is far from a being a continuous process and even further from achieving the efficiency figures of an average paper machine. An important time loss is related to the unwinding section as reels need to be replaced and, moreover, paper brakes inside parent reels may require additional stops and additional time in order to restore the converting line into operational mode.

MTorres solutions reduce nearly to zero such time losses and, moreover, the unique FACT tension control system guarantees a proper and constant feeding of the rest of the converting line eliminating all the stops related to sudden and unexpected variations of tension. Benefits are deeply linked with the peculiarities and exigencies of each customer and, with the help of our PAYBACK tool, we are capable of providing specific replies to specific cases.

With the support of Goma-Camps a real case study will be examined thanks to their experience of several years with MTorres solutions. With their direct knowledge and experience we will show concretely the added value brought by MTorres solutions into any converting line.

Conference Abstracts

TECHNICAL SESSIONS 4 to 6 - 12 APRIL 2017 Technical Session 5: Converting technologies, maintenance, spray and lotions

Lucart Laval PM10 paper machine speed up project including doctoring system replacement Danilo Calamari, Technology Manager Paper Mill, Lucart S.p.A, Italy Maurizio Tomei, Sales and Technical Engineer, Oradoc S.r.l., Italy 12:40 – 13:00 PM10 Laval, a Crescent Former tissue paper machine with a Yankee dating back to 1988 with a maximum linear speed of 1280 m/min. Moreover, the paper format requested in converting implies trims due to the Yankee width.

For these reasons, the Lucart management decided to fund a project aiming at improving performances of Laval PM10 and undergo a thorough revamping in order to increase production - with a target linear speed of 1600 m/min - and optimize profiling.

Lucart envisaged a complete overhaul of the PM10, including the Yankee substitution with a wider one (to reach 3800 mm paper format width already trimmed), a modified and updated air system and bigger diameter felt rolls, felt conditioning update and some improvement in the stock preparation.

Within this picture, the doctoring system, which was obsolete, needed to be changed as well in order to adapt to the wider Yankee. These components require regular attention and tune-up that help production optimization and save downtime and lost revenue every time an issue comes up.

This said, Oradoc developed a fully customized solution for Lucart’s needs. To meet the plant’s requests, Oradoc installed its standard flexible creping doctor and a new type of rigid doctor in both cut and cleaning positions, with an innovative open design cartridge that allows better cleaning by minimizing dust and dirt deposits, easier removal and fast stick out change.

Besides, given that removing doctor blades can be a hazardous activity, Oradoc completed its supply with a new device to increase Yankee safety operations by optimizing the blade change process, allowing the operator to keep at a greater distance from the working paper machine.

In this way, Oradoc’s technology not only allowed Lucart to get the most out of its machinery, but it also helped increasing safety for all operators.

Conference Abstracts

TECHNICAL SESSIONS 4 to 6 - 12 APRIL 2017 Technical Session 5: Converting technologies, maintenance, spray and lotions

A three-part approach to improve runnability in production and converting

Andrea Friedrich, Key Account Director for Pulp & Paper Industry, Isra Parsytec, Germany 13:00 – 13:20

This paper offers a three-part approach that can help increase machine speeds in tissue production, while reducing downtime caused by sheet breaks, and improving production efficiency in converting.

The sum of the parts results in a compelling and synergistic approach to improve and benchmark a mill’s performance.

The three components of the system are integrated into a single solution. Having only one component reduces the value derived from the other components.

The benefits of the complete solution include improved runnability in production and converting and higher off-machine tissue quality, and accurate information on how specific process adjustments i mprove quality with objective and quantifiable data. In addition, corporate understanding of where investments and resources can be directed for final product quality and overall equipment efficiency can be enhanced.

The first two prongs of the approach are to install a web inspection system (WIS) and web break monitoring (WBM) on the tissue machine to reduce defects and improve runnability. The third involves the use of unwind control system (UCS) and / or web monitoring system (WBM) in the converting line to reduce the number of sheet breaks.

Consumer or industrial roll line? Now you can hove the two in one Guido Finoccki, Managing Director, Universal Tissue Technology, Italy

Currently production lines are either dedicated to toilet paper, or to kitchen towel, or are so called swing lines, capable of making both categories. Industrial roll lines are looked at as different technology and they are kept separate from consumer ones.

The market however is changing rapidly and one example is the invasion of big roll diameters into the kitchen towel space, which offers lower costs and longer rolls. For tissue producers there is now a different choice: truly flexible lines that can fully meet all the technical needs for consumer and awayfrom-home products.

Our presentation aims to bring to the attention of tissue experts this new type of converting lines where the same technology can convert all roll products.

Conference Abstracts

TECHNICAL SESSIONS 4 to 6 - 12 APRIL 2017 Technical Session 6: Dewatering - Improvements and energy savings

Faster changeover and higher output with new wrapping approach Stevan Kalos, Sales and Marketing Director, STAX Technologies, Serbia 14:30 – 14:50 For decades there has been hardly any improvement in tissue wrapping. However, new equipment for tissue roll wrapping has now been developed, capable of wrapping multiple formats and tissue roll types, using different components and technologies to wrap tissue rolls. Featuring flexible design, it can reduce changeover time by up to 60%.

Altogether, it leads to an average increase of 42% in capacity with improved final product quality. This new equipment type will establish higher standards in the tissue roll wrapping industry.

Improving wet end efficiency with latest in forming fabric technology Chad Martin, Forming Product Business Leader, AstenJohnson, USA 14:50 – 15:10 In this paper, the latest evolution of forming fabric construction with structured yarn technology will be will be discussed. Next-generation forming fabrics yield significant reductions in forming fabric fiber carryback, resulting in fewer wet end breaks and improved efficiency.

The low caliper of these designs allows for either lower energy consumptions and/or increased machines speeds through improved sheet dryness off the former. Sheet formation is improved and pin holes are reduced as a result of the fine forming surface, targeted MD/CD tensile ratios are maintained.

Improved fabric stability leads to very low fabric width contraction, which is important for today’s high speed crescent formers.

Evidence of these advantages will be supported through multiple case studies.

Conference Abstracts

TECHNICAL SESSIONS 4 to 6 - 12 APRIL 2017 Technical Session 6: Dewatering - Improvements and energy savings

New fabric design for higher dewatering, more sheet bulk, and lower drive loads Frank Cunnane, Product Specialist, Cristini, USA 15:10 – 15:30 Cristini fabric designers have developed a weave pattern that uses SSB technology in a much tighter construction than previously thought possible, designed to provide improved drainage with surprisingly high FSI numbers. This is a family of extremely fine fabrics (SOFTLITE) designed specifically for tissue and toweling grades. This family features high sheetside planarity for improved Yankee adhesion, resulting in better creping.

More vertical drainage through the fabric reduces the internal void volume and induces the fabric to move more water. This is accomplished by tightening the structure without reducing its drainage Index (DI) or permeability. The MD yarns are “double bound”, i.e., two binding yarns weave in unison to provide stability and reduce exposure to backside wear. Many small drainage holes are shown to be better for overall water removal than non-uniform drainage patterns in “looser” structures, as is predicted by Darcy’s Equations.

The back side of these woven structures is made to be particularly open to provide easy egress for water, but also to “skate” over stationary elements and thereby reduce drag loads. Cases presented demonstrate reduced drag loads by as much as 7% compared to the designs run previously.

Variable speed turbo blowers can cut vacuum system energy use by 30 - 70% Jukka Lehto, Managing Director and CEO, Runtech Systems Oy, Finland 15:30 – 15:50 Runtech Systems has developed new Ecopump technology for tissue machines vacuum systems.

Ecopump technology is based on variable speed turbo blowers and can cut the energy costs of the tissue machine vacuum system by some 30-70% compared to more traditional technologies.

In addition, Ecopump blowers are totally water free and thus fresh water consumption of the whole tissue machine can be reduced while at the same time the water handling and/or water treatment costs of the complete vacuum system fall to zero.

The fully adjustable speed of Ecopump turbo makes it easy to optimise the vacuum system to meet the varying operational demands of the tissue machines. This enhances the operational efficiency of the vacuum system compared to any other vacuum systems available.