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Thursday, 26 August 2021 10:57

Nonwovens Lamination

What is Lamination?

Lamination is the process of manufacturing a material in multiple layers, so that the combined physical and mechanical characteristics of each layer make for a stronger, more resilient composite material.

  • What is Lamination?
  • Nonwovens Lamination main areas of application
  • Nonwovens Lamination techniques and advantages
  • The Best Nonwovens Lamination machine

The earliest examples of lamination made use of natural adhesives such as beeswax, gums, tar and substances derived from animal bones. As technology progressed, we discovered the use of sealing wax as the first hot-melt adhesive. In the 1930s a wet lamination process (with the use of solvents) was used to bond shirt collars (a woven fabric) with cellulose acetate. This process was deemed inconvenient, and by 1948 progress was made in dry lamination using polyvinyl acetate plasticized with dibutyl phthalate.

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Nonwovens lamination, in particular, is the process of bonding two or more layers, at least one of which is a nonwoven fabric, with the objective of obtaining improved strength, stability, sound insulation, appearance, or other properties. Although less expensive to manufacture, nonwoven fabrics tend to be weaker than woven ones, and the lamination process comes into play just when there is the need to strengthen this nonwoven material for a variety of uses.

The bonding is typically done with the use of adhesives (or heat) and pressure, making it possible to manufacture nonwovens products, equipped with a waterproof layer, that are breathable, soft, comfortable and suitable for printing.

Shortly after the beginning of the industrial production of disposable diapers, nonwoven laminated products, such as the textile backsheet, appeared. From the early days of dry lamination various adhesives were produced, including hot-melt powders.

Breathability was an issue with lamination in the early days, but the processes used today are capable of producing breathable, porous materials that maintain their waterproof properties.

Published in European News

A.Celli Paper, together with the Smurfit Kappa Roermond Papier team, has successfully rebuilt and started up the PM3 of the Roermond plant dedicated to the production of packaging paper.

A.Celli Paper announces the completion of the rebuilt PM3 start up on the 24th of June, with total satisfaction of our client, Smurfit Kappa Roermond Papier, both for the performance achieved and for the compliance with the planned program, despite the difficulties related to the global pandemic.

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The rebuilding interventions carried out by A.Celli Paper on the Smurfit Kappa’s PM3, a line dedicated to the production of 1000 tons/day of 2-layers liner packaging paper with basis weight ranging from 125 to 220 gsm and a width of 5090 mm, involved:

  • The press section, with the substitution of the whole frame and the change of the press loading system from pneumatic to hydraulic. 
  • The first group of the pre-dryer section with four new dryer cylinders and three vacuum rolls, including the relevant new hood. 
  • Mechanical and piping erection services

Said interventions took a total downtime period of 21 days and the commissioning phase ended on the 21st of June.

Mr. Sjon Vrieze, Technical Operations Manager of Smurfit Kappa Roermond Papier, says: “We were able to resume production on the evening of June 24, and the machine is running stable since then. Uptime is above target, speed is on target and the quality achieve is above target, so from the point of view of the machine performance we are happy so far. I wish to send my regards to all the A.Celli colleagues who have worked hard to get the job done in Roermond.”

SMURFIT KAPPA ROERMOND PAPIER – Company Profile

Smurfit Kappa Roermond Papier is a company started in 1937 and part of the Smurfit Kappa Group, an international brand with 350 branches in 35 countries and leader in Europe for the production of corrugated packaging, containerboard and “bag in box”. In 2020, Smurfit Kappa Roermond Papier produced 635,000 tons of recycled paper from over 1.3 million bales of waste paper.

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Kochavinska Paper Factory and A.Celli Paper signed a turnkey supply contract for a high efficiency iDEAL® tissue machine.

A.Celli Paper is proud to announce that it will supply a tissue production line to the European tissue brand Kochavinska Paper Factory JSC, one of the Ukrainian leading producers of base paper and sanitary tissue products manufactured from waste paper.

A.Celli Paper’s scope of supply comprises a complete tissue production line including an high efficiency iDEAL® START 1.500 tissue machine, equipped with an iDEAL® Forged_YD Yankee cylinder. The new tissue machine, highly appreciated for low consumption, convenience and compactness, will have a design speed of 1.500 m/min with a reference production up to 80 t/d. An R-WAY® reel handling system and a three-ply E-WIND® T80S slitter-rewinder complete the supply.

The supply will feature A.Celli Paper’s state-of-the art tissue technology, including two complete stock preparation lines, one for long fibers and one for short fibers. Top-notch mill engineering and a wide array of services provided by engineers with extensive experience in design and field activities are also included in the scope. Furthermore, the delivery will include an A.Celli Paper advanced DCS controls, innovative industrial automation applications and integrated systems.

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The manufacture of the machinery will take place in Lucca, Italy and is expected to complete within 12 months.

The project assumes the construction of a facility for the production of pulp-based tissue products to meet growing demand for high quality tissue products. It will enable Kochavinska Paper Factory JSC to enter the higher quality retail tissue segment, double its tissue production capacity and improve operating efficiency.

"We are very pleased to have signed this agreement with A.Celli, and we are proud to be developing our plans for technical and commercial expansion using the advanced technologies they offer” said the Head of the Supervisory Board and a major shareholder of JSC Kochavinska Paper Factory Mr. Mikhail Tytykalo, and the Head of the Board Mr. Roman Pyrig. "The iDEAL® PM line for hygiene products, which will be the heart of our factory, guarantees us great flexibility in production, high product quality and a big advantage in terms of energy savings. The success of our proposal depends on these decisions".

Kochavinska Paper Factory - Company Profile

Kochavinska Paper Factory is one of the largest producers of recycled base paper and tissue and is located in western Ukraine. The company dates back to 1938, when the plant was built with the involvement of experts from Germany, Poland and Sweden. In the 1990s, the factory underwent voucher privatisation and is currently owned by 173 shareholders.

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Thanks to the collaboration between the teams of the two companies, the start-up of the Tissue rewinder installed in the Prachinburi plant in Thailand was successfully completed.

A.Celli started up the rewinder supplied to Berli Jucker Cellox Co. Ltd, a subsidiary of the Berli Jucker Public Company Limited (BJC), in full compliance with the agreed time despite the difficult situation caused by COVID19 pandemic.

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The A.Celli E-WIND® T100 Tissue rewinder was designed to process 3,000 mm diameter paper rolls with a width of 2750 mm and a basis weight ranging from 13 to 45 gsm, all at an operating speed of 1700 m/min. This will enable Berli Jucker Cellox Co., Ltd to produce up to 90 tons of tissue paper per day. Last but not least, the rewinder was equipped with the trimming removal system.

Mr. Chusak Soysungvarn, Berli Jucker Cellox Co. Ltd’s Prachinburi Plant Director, says: “It was difficult to put into words the happiness you get from seeing the first tissue reel came out from the A.Celli rewinder. We have focused heavily on this expansion project to enhance manufacturing efficiency, energy consumption and quality level to serve our customers in the best possible way. The machine definitely fulfilled our wishes and we were really satisfied by the excellent collaboration and services provided by the A.Celli team”.

BERLI JUCKER PUBLIC COMPANY LTD - Company Profile

Berli Jucker Public Company Limited (BJC) is a company with more than 135 years of history at the forefront of the trade, manufacturing and service fields in Thailand. Originally, BJC engaged in rice milling, mining, timber, shipping, importing, and other activities that laid a foundation instrumental for Thailand’s progress towards an “industrial” stage. After World War II, BJC diversified its operations into manufacturing, packaging and distribution.

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The new Tissue rewinder, located in the town of Dej in Romania, was started up thanks to the field support of the A.Celli team and the precious collaboration of the Romanian team.

It is with pride that we announce that the new E-WIND® T100 Tissue rewinder supplied to the prestigious Romanian company MG TEC Industry S.r.l was successfully started up at the end of April in full compliance with the project objectives in terms of timing and product quality agreed with the customer

MG TEC Industry isa new Romanian company founded in 2018 in the Transylvanian town of Dej. The main objective of their project is the construction of a greenfield plant focused on the development of a production line for tissue paper, absorbent products, hygienic and sanitary products.

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The A.Celli E-WIND T100® will be a part of the Tissue line dedicated to the production of paper with a width of 2850 mm and a basis weight ranging from 13 to 45 gsm. Thanks to the line's operating speed of 1600 m/min, it will be possible to produce up to 100 tons per day of the highest quality tissue paper.

Another success that, combined with the satisfaction of MG TEC Industry S.r.l., makes us more and more proud of our technology dedicated to the slitting and winding/rewinding of any type of paper on the market.

Mr. Hasmasan Vasile, MG TEC Industry Plant Administrator, says: “Special thanks go to our operators who have successfully managed all the start-up steps despite the circumstances caused by the pandemic. The assistance of the A.Celli team was fundamental: we were able to count on excellent support both on the field and remotely, directly from Italy. "

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A.Celli Paper assisted the PT. Dayasa Aria Prima (Dayasa) team in every step of the process to ensure a successful start-up of the paper machine converted to the production of Corrugated Medium by applying PMT technology.

A.Celli Paper is proud to announce that on Saturday March 13th PT. Dayasa Aria Prima (Dayasa), a subsidiary of PT. Fajar Surya Wisesa (SCG - SIAM CEMENT GROUP), has successfully started-up the completely rebuilt PM#1 located in their Gresik plant.

Given the current global situation and the consequent travel restrictions, the start-up was carried out remotely thanks to the continuous support of A.Celli Paper team and a detailed commissioning program with specific documentation.

The 5600 mm wire machine has been converted from the production of coated paper to Corrugated Medium with a design basis weight of 90 gsm at a design speed of 1200mpm.

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The A.Celli Paper/PMT supply included:

  • PMT Shoe Press with Deflection-Controlled Roll
  • Major rebuild of the dryer section with the installation of Vacuum Rolls, Stabilizer Boxes and a new Rope Less Threading System

With the acquisition of PMT and the full integration of the PMT engineering, A.Celli Paper is now in the position to supply machinery equipment for all kind of paper.

This supply will be added to the existing A.Celli E-WIND P100 Paper Rewinder equipped with the Slittomatic™ Web-In automatic slitting units positioning system and with the addition of the spool storage.

The successful rebuild carried out for SCG, which follows the supply of a new paper rewinder in one of their Vietnam plant and the rebuild of an existing rewinder made by another manufacturer, is a great achievement for all our Asian customers.

This is also a perfect demonstration that no matter the obstacles due to the global pandemic, A.Celli will always be by your side.

Published in Asian News
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The preparation of reels bundles is an operation that requires great precision, attention and speed. This is to ensure safe packaging capable of preserving the quality of the reels during transport, to avoid the occurrence of bottlenecks in production and to fulfill orders in the shortest possible time.

The efficiency of the packaging and storage process, therefore, contributes to the optimization of the entire production process and allows for a timely response to market demands. For this reason, systems for the automatic preparation of reel bundles play a fundamental role for companies that want to obtain or consolidate a competitive advantage on the market. Thanks to the use of robots it will in fact be possible to prepare flawless paper, tissue and nonwovens reel bundles while optimizing time, space and costs.

The automatic reel bundles preparation process

Before describing its advantages, let's briefly see how the automatic preparation of reel bundles takes place:

  • The finished reels coming out the production line are transferred to the packaging line, where they are labeled and subsequently stacked by a special robot, thus forming the bundle of reels according to the packaging recipe provided by the customer. The robot will also apply the cardboard, plastic or other parts discs to complete the package.
  • The bundle thus obtained is automatically sent to the wrapping area, where it is packaged by machinery called wrappers.
  • In certain cases, for example for bundles of small-format reels or for warehouse management needs expressed by end customers, the packaged bundle is sent to the palletizing area. In order to stabilize the palletized bundle and preserve its integrity, a second packaging is applied.

To ensure high process automation, it is also possible to interface the robot with weighing, wrapping and labeling systems.

Regarding the automatic palletization of bundles, there are several solutions:

  • Cartesian palletizer (with 2, 4 or more axes): a simple and compact system, very reliable and flexible. Ideal in case of high work intensity, where high speeds and positioning accuracy are required.
  • Layered palletizer (with stacking from the top or from the bottom): a solution that involves grouping by layers and transferring the product by means of a translating platform.
  • Column palletizer: allows you to build multiple columns of bundles or pallets and is useful in cases of very high products or products of different heights.
  • Anthropomorphic robot: among the most versatile, flexible and fast solutions. It adapts to the handling of products that are very different from each other and is perfect in the case of confined spaces as it provides a large work area, extended to 360 °, with a minimum footprint.

The validity of each solution depends on the type of product, the packaging line (low, medium or high intensity) and the space actually available in the company. Whatever the solution adopted, automation introduces significant competitive advantages.

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The advantages of automatic bundle preparation

Not only companies that handle large daily productions can benefit from the use of an automatic bundle preparation system, but also those characterized by small to medium-sized production processes.

Reel packaging requires physical effort, high precision and expenditure of time. The use of robots allows you to obtain:

  • Greater speed and 24/7 operations, with a consequent increase in productivity: the result varies depending on the power and type of robot used, but on average the speed of operations is doubled compared to the use of manual work. A robot, for example, is able to process over 200 rolls per hour without the need for pauses.
  • Greater safety for operators and reduction of accidents at work: a robot can move and lift the loads to be stacked on the pallet effortlessly and more safely.
  • Homogeneous quality standards and packaging safety: a robot is able operate in a precise, safe and stable way; on the contrary, manual palletization is subject to possible errors which can also cause damage to the goods during transport operations.
  • Flexibility and customization: a robot can be integrated with numerous components - for example grippers, arms, rollers - adaptable to the configuration of your packaging system.

To achieve maximum efficiency and order processing speed, it is equally important to evaluate the possibility of automating the entire reel handling and packaging process by relying on suppliers, such as A.Celli, able to offer integrated and customizable solutions.

A.Celli R-WAY®: the customizable Automatic Packaging system

A.Celli offers a modular, flexible and customizable system for reel handling and packaging, adaptable to any layout and any production line. Thanks to the R-WAY® Automatic Packaging System it is possible to manage the entire packaging process:

  • Reel transfer from the production line to the packaging line;
  • Labeling of the outer surface of each reel and the inner surface of the core
  • Automatic preparation of reel bundles by means of robots;
  • Bundles packing, weighing and labeling 
  • Possible palletization and second packaging

The A.Celli solution can also be integrated with the customer's ERP (Enterprise Resource Planning) and is able to provide log files and specially structured access tables, in which production orders and details regarding individual reels and processed bundles will be stored.

A.Celli, among the various integrable solutions, also offers a reel data tracking and archiving system, iREEL, which allows you to keep the detailed history of the product, from the mother roll to each individual reel of finished product.

Conclusions

Companies increasingly have the need to increase the efficiency and reliability of production lines. Automation systems can greatly contribute to meeting this need.

If you want more information on how to improve the management of your packaging process, download our free eBook “The ultimate guide to Automatic Reel Packaging” now!

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Published in European News
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How the Berry Global Statesville plant increased its efficiency, safety and productivity with the A.Celli TVC B Automated Guided Vehicle.

Berry Global Group Inc., headquartered in Evansville, Indiana, is a Fortune 500 company and a leading global supplier of a broad range of innovative rigid, flexible, and nonwoven products used every day within consumer and industrial end markets. Committed to its mission, “Always Advancing to Protect What’s Important”, Berry Global proudly partners with its customers to provide them value-added protective solutions that are increasingly light-weighted and easier to recycle or reuse. The company serves a wide range of markets with its solutions, including the beverage, construction, filtration, food, healthcare, household, and hygiene sectors.

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  • Nr. of Employees: 47.000+
  • Nr. of Facilities: Over 290 across the globe
  • Industrial Sector: Packaging & protection solutions

The challenge 

The customer's objective was clear: to have the possibility of exchanging the Master rolls between the rewinders of the different lines of equal format present in its Statesville, North Carolina, manufacturing facility. This with a view to assuring both the maximum degree of efficiency and safety for typically critical productions and an increase in productivity, due to the elimination of variables introduced by manual guidance and the lower waste ensured by automatic management.

Fortunately, we had just the right solution for them in our product portfolio...(Click the banner below to donwload the full case study!)

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Among the main features of quality Tissue paper there are certainly a high bulkiness and softness. How can this be achieved by using a conventional configuration with a single press nip and, at the same time, decrease energy consumption? The answer is our A.Celli X-Roll solution.

The demands of the Tissue industry

Tissue paper producers all over the world are constantly looking for solutions that allow them to offer high quality products without possibly increasing production costs, among which those linked to energy consumption certainly stand out. In fact, as highlighted in the previous article about water management in a Tissue plant, we recall that the final evaporation eliminates a relatively small part of the total water present in the fibers, but involves a considerable waste of thermal energy supplied by steam boilers (for the operation of the Yankee Dryer) and by an aerothermal system.

With this in mind, a series of studies conducted on pilot lines led to the conclusion that the key to obtaining the best results in terms of bulk without negatively affecting consumption could be represented not so much by the pressing phase that takes place in the nip between the suction press roll and the Yankee Dryer, but from the previous pre-drying phase carried out by means of the suction sector of the press roll itself located immediately before the nip.

The results of the studies described above show, in fact, that a significant impact on the output of the production process is due to the degree of dryness of the felt and, therefore, by the ability of the latter to absorb water from the Tissue paper. Starting from this, A.Celli has developed a solution to optimize the configuration with a single press nip in order to obtain Tissue paper of equal quality and, at the same time, a reduction in energy consumption associated with the drying area.

Conventional configuration with a single press nip

Let's analyze the operation of a conventional Tissue machine with a single press:

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In this case, the pressing that takes place in the nip formed by the suction press roll and the Yankee Dryer will be contextual to the action of the vacuum sector inside the suction press roll itself. The latter consists of a perforated cylinder equipped with a metal shell and covered in synthetic material, and the holes have the task of retaining the water drained by the pressing action. Inside the shell there is a suction box whose task is to create a depression inside the press itself by connecting to a vacuum pump, thus sucking the air present in the holes in order to allow the water to be housed inside them. This water will then be extracted by centrifugation as soon as the effect of the vacuum itself disappears..

In this configuration it is also possible to use a steam box, positioned in correspondence with the suction press roll and just before the nip, whose purpose is to increase the water temperature and therefore decrease its viscosity. In this way, during the pressing phase the water is able to flow better into the felt and into the holes of the suction press roll.

However, the positioning of the steam box is not optimized from the point of view of efficiency as it acts in a point where the Tissue paper still has a high amount of water. In addition to this, the case thus positioned is subject to clogging due to the fiber fragments expelled by centrifugal force from the felt during the passage on the suction press roll. The consequence is that these fragments, once the steam box is activated, will be thrown at high speed against the Tissue paper, causing breakages.

A.Celli X-Roll 

As we have said, A.Celli X-Roll's goal is to combine the quality of Tissue paper obtainable using the traditional configuration with a lower total energy consumption.

To achieve this result, the goal was to ensure a high degree of dryness of the felt before the pressing phase, so as to reduce the power to be supplied in the drying section during the subsequent evaporation phase. While the conventional configuration first envisages the combined action of the steam box and the vacuum followed by the action exerted by the nip, A.Celli X-Roll uses in succession a suction roll, a steam box and a blind press:

  • In the first place we will have the action of vacuum by means of the suction roll. By doing so, a part of water will be eliminated, thus increasing the degree of dryness of the felt before the next two phases.
  • In this way the steam box, positioned between the suction roll and the press nip, and a flat vacuum box will act in a point where the felt has already been partially dried by the previous process, increasing the temperature of the sheet more efficiently and eliminating the risk of clogging of the steam box itself.
  • Finally, the action of the nip between the Yankee Dryer and the blind press will ensure that the sheet proceeds towards the evaporation area of the Tissue machine with a high degree of dryness and with the same bulkiness obtainable using a conventional configuration.

In terms of energy savings, we were able to detect, from tests performed on a pilot line, that the A.Celli X-Roll solution leads to a 4% increase in the degree of dryness of the paper exiting the pressing process compared to the conventional configuration,which translates into an energy saving of over 16% in the drying phase.

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Aktül Kağıt is a company that produces tissue paper from 100% virgin wood pulp, managing Private Label products for the main local and foreign chains. It also supplies high quality jumbo rolls for numerous converting facilities, located both in Turkey and abroad.

The collaboration between A.Celli Paper and Aktül Kağıt started at the beginning of September since the Turkish company was looking for a customizable, plug-and-play cutting solution, perfectly adaptable and compatible with any standard rewinding system or complete tissue line.

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To meet the needs and requirements of the Tissue producer, A.Celli Paper showed its E-WIND® T80S solution: a latest generation, modular and fully automated rewinder, running at 1.000 mpm, with built-in electrical cabinets and capable of managing products that involve a specific volume, diameter and cutting format while also guaranteeing extra capacity during production peaks.

To confirm the great versatility of the machine, suffice it to say that it only took our customer 2 weeks to start up the machine, from the date of arrival of the shipment to the day the rewinder started to process paper. Moreover, in addition to this extraordinary record, with an additional week we were also able to reach the guaranteed contractual productions.

Thanks to this supply A.Celli Paper has offered its customer a considerable leap in quality built on three pillars: the minimization of installation times; cost containment and the achievement of long-term performance.

Published in European News
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