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Wednesday, 05 August 2020 07:04

Toscotec receives forth turnkey order from WEPA

Toscotec will supply an AHEAD 2.2S tissue line on a full turnkey basis to WEPA Piechowice mill in Poland. The project is planned in a short time frame, with start-up set for the third quarter of 2021. This is a repeated turnkey order for WEPA Piechowice mill, where an AHEAD 2.0S machine supplied by Toscotec on a turnkey basis came online in 2017.

WEPA selected Toscotec for the turnkey supply of the last three tissue machines it installed since 2015, including WEPA Lille in France, WEPA Giershagen in Germany and WEPA Piechowice. Previously, Toscotec had supplied other two complete machines to WEPA Sachsen in Kriebstein, and to WEPA Giershagen. This new AHEAD 2.2S in Poland will be the sixth tissue line that Toscotec delivers to the German Group, in addition to the numerous rebuilds it completed over the years for the wet end and dry end sections of WEPA’s existing machines. Recently, WEPA Giershagen PM19 achieved the constant operating speed of 2200 m/min, setting a new world record in the tissue industry for machine speed in continuous running conditions.

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The new AHEAD 2.2S machine features a 2750 mm sheet trim width and a design speed of 2200 m/min. It will produce over 40,000 t/y of premium quality tissue mainly for the Away-from-Home market, made of either virgin or deinked pulp (DIP). The AHEAD 2.2S machine is equipped with Toscotec’s shoe press technology TT NextPress, a third-generation-design TT SYD, gas-fired hoods with several stages of energy recovery, and an in-line shaft puller at the pope reel. The machine is designed for the implementation of digital technology and advanced control systems supplied by Toscotec and Voith.   

The project also includes the complete stock preparation, Toscotec’s patented TT SAF (Short Approach Flow) for high operation efficiency, the complete electrical and control system, including the DCS and the QCS and the dust and mist removal systems. The vacuum plant, air compression station, bridge cranes, roll handling and hall ventilation systems complete the turnkey supply. 
WEPA also purchased a full service package including the detailed mill engineering, the plant and the machine erection, commissioning, start-up supervision and training. 

Martin Krengel, CEO of WEPA Group said, “As in the past, we have great confidence in Toscotec and are convinced that we have the right partner with the latest technology on our side for this project. We continue to trust Toscotec for their commitment to our efficiency and product quality, their operational flexibility and their ability to fully meet our demands.”

At the Piechowice site, WEPA produces for the Away-from-Home market. Udo Raumann, Managing Director of WEPA Professional said, “The new line is an investment in our future. We modernise the production site by replacing the existing crepe line with state-of-the-art machinery for tissue production.”

Alessandro Mennucci, CEO of Toscotec, said, “We are proud of our strong relationship with WEPA, which made our two companies grow together as trusted partners for over 20 years. Just like we did in the past, Toscotec will line up its most advanced technology, know-how and expert team to manage and successfully complete this new turnkey project.”

About WEPA  
The WEPA Group is a family business operating throughout Europe and offers sustainable and innovative hygiene solutions that provide a safe feeling of hygiene and contribute to the well-being of millions of consumers all over Europe every day. With 3,800 employees, the WEPA Group produces hygiene paper products such as toilet paper, towel paper, handkerchiefs and napkins at 13 production sites in Europe. WEPA is one of the three largest European manufacturers and is market leader in the production of hygiene paper made of recycled fibres. The annual turnover amounts to approximately 1.3 billion euros. In the consumer business unit, WEPA is the specialist for the private label of European retailers. The Professional business unit, with the brands BlackSatino and Satino by WEPA, stands for sustainable and professional hygiene solutions, which are used in public washrooms, the industry, offices or health care for example. The headquarters of the WEPA Group is in Arnsberg, North Rhine-Westphalia.

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German containerboard manufacturer Aviretta selected Toscotec to rebuild the post dryer section of its PM4 at Ettringen mill, Bavaria. PM4 produces test liner and fluting from 60 to 130 g/m². Start-up is scheduled for the fourth quarter of 2020. 

Toscotec will supply nine TT SteelDryers of over 7 m face width, which will replace PM4’s existing cast iron cylinders. The scope includes condensate spoiler bars, steam joints, bearings and housings, and spares. Aviretta also ordered a comprehensive service package, with engineering, on site disassembly, erection, commissioning, and start-up. 

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Carl Pawlowsky, Executive Partner of Aviretta GmbH, said: “I was very impressed with Toscotec’s technical proposal, due to the quality of its TT SteelDryers, their wide installed base, and Toscotec’s substantial experience in the field. We expect to be able to count on a very reliable product with high performance in the long term.”

Giancarlo Gianlorenzi, Toscotec’s Sales Manager, said, “We are proud to be recognized in a technological market such as Germany. With this new project, Toscotec is confirmed as the benchmark supplier of dryer section rebuilds of large format and high speed paper machines. We are happy to start a new partnership with Aviretta, and are confident that our TT SteelDryers will satisfy their reliability and quality requirements. The schedule of the rebuild is rather tight, but we will meet their expectations.”

About Aviretta GmbH 
Aviretta is a German containerboard manufacturer of medium and fluting grades, based in Ettringen, Bavaria. It annual production is approximately 170,000 tonnes, with a range of containerboard grammages from 60 g/m² to 130 g/m². Aviretta uses 100% recovered fibres certified by FSC® standards. 

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Core board manufacturer Papertech exceeded the targets of production increase originally set for the rebuild of its PM1 at Tudela mill, Spain.   
At the end of 2018, Toscotec carried out a turnkey rebuild of the dryer section, installing 20 new TT SteelDryers. The supply included TT AirTail, an advanced rope-less tail threading system, which features a simple air flow regulation that guarantees stable tail threading for any basis weight. PM1 came online at the beginning of 2019 and successively exceeded the production targets Papertech originally set for this rebuild. 
Mr. David Rubio, General Manager of Papertech and Dr. Luis Miguel Calvo, Mill Manager, openly discussed what they achieved with their rebuild project.

Who is Papertech? 
Mr. Rubio: Founded in 1952, Papertech is a core board specialist in Spain. The Group has four paper mills in Europe and Asia: Tudela mill in Northern Spain, two mills in Indonesia and one in China. A couple of years ago, Sonoco Corporation, the global packaging company, bought 100% of the company’s shares. The group manufactures paper tubes and cores and other industrial applications such as cones for the textile industry, laminates, composite cans and dividers. 
Currently, Tudela mill has an annual capacity of 60,000 tonnes, and the group total production is approximately 300,000 t/y.

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PM1’s rebuild was your first cooperation with Toscotec. Why did you select Toscotec? 
Mr. Rubio & Dr. Calvo: Our goal was to increase production. Out of the various technical solutions we evaluated, Toscotec gave us the most advantages. Firstly, with TT SteelDryers you can customize the diameter, and they offered a larger diameter than that of the cast iron cans we had; secondly, TT SteelDryers feature a bigger drying surface than cast iron dryers of the same face length. Basically, maintaining unchanged the overall length of the dryer section of the paper machine, we significantly increased our drying capacity, due to the larger diameter and drying surface of the new steel dryers. As a result, we were also able to preserve our existing hood, which is still working well. Toscotec had many successful references of similar rebuild projects and we were rather impressed with their extensive experience. 

Why did you choose a turnkey supply? 
Mr. Rubio & Dr. Calvo: This has been a key part of our growth strategy and we wanted to have one single company in charge and responsible for every aspect of the supply, including the mechanical and electrical part and services. Toscotec supplied all of the equipment and provided erection, supervision, commissioning and start-up assistance. They did a great job, we are very satisfied with their management of this turnkey supply.  

Let’s focus on the project implementation. Are you satisfied with time management? 
Mr. Rubio & Dr. Calvo: We were very focused on the machine downtime, because any delay would have put us in the difficult position of handling unplanned downtime, which is very costly. Toscotec’s team managed the project schedule beautifully. Our machine downtime was executed exactly as planned. It was perfect!

Did you achieve your production targets? 
Mr. Rubio & Dr. Calvo: Yes, we achieved our targets of production increase. Actually, we surpassed the targets we had originally set for this project. TT SteelDryer lived up to our expectations and delivered a high drying capacity, which allowed for this production increase. 
Toscotec’s rope-less tail threading system has been another upgrade of our existing line. It was specifically designed for low speed and high basis weight, because we were to apply it also to our higher basis weight range. As we went along, the expertise of our operators increased, which contributed to improve its final efficiency. Now, we are happy with it. 

How would you describe the cooperation with Toscotec? 
Mr. Rubio & Dr. Calvo: The cooperation has been very profitable. Toscotec is a very professional and flexible supplier, who delivered and implemented a successful rebuild. Their team provided fast responses and assistance whenever needed, solved problems and coordinated all the involved parties in the best possible way. 

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WEPA Giershagen is steadily operating its Toscotec-supplied AHEAD-2.0S tissue line (PM19) at the speed of 2,200 mpm. PM19 came online in October 2015 and after a machine speed-up, reached the constant speed of 2,200 mpm. Based on this result, WEPA sets a new world record in the tissue industry for machine speed in continuous running conditions.

The AHEAD-2.0S line is dedicated to the production of high quality tissue from 15 to 16.5 gsm basis weight. WEPA maximized its efficiency and achieved top performance in terms of production capacity with low energy consumption. PM19 production fulfils the quality parameters of WEPA’s super-soft toilet paper.

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Frank-Peter Folcz, Plant Manager WEPA Giershagen, said: “Concerning the layout of the machine, we decided for a double press with 2x 120 kN/m line load. This was a new way for us, but it was exactly the right way. In order to produce paper in this speed range in a stable manner and with the highest performance, you do not only need a good machine - motivated and very well-trained staff is just as important. This combination is key to success”.

Riccardo Gennai, Toscotec Sales Manager, said, “We congratulate WEPA on the incredible job they did on this Toscotec machine. Our longstanding partnership has led to many achievements, and taking PM19 to the constant speed of 2,200 mpm is certainly a great one. This is what we work for everyday at Toscotec: supporting our customers’ success with the best technology and services. It is a satisfaction for us to see that PM19 still has untapped drying capacity, given the considerable margin both in terms of steam pressure and hood temperature.”

From 2006, Toscotec supplied the WEPA Group with 5 complete tissue lines - three of which on a full turnkey basis - and eight rebuild projects in paper mills in Germany, France, Italy and Poland.

About WEPA

The WEPA Group is a family business operating throughout Europe and offers sustainable and innovative hygiene solutions that provide a safe feeling of hygiene and contribute to the well-being of millions of consumers all over Europe every day. With 3,700 employees, the WEPA Group produces hygiene paper products such as toilet paper, towel paper, handkerchiefs and napkins at 13 production sites in Europe. WEPA is one of the three largest European manufacturers and is market leader in the production of hygiene paper made of recycled fibres. The annual turnover amounts to approximately 1.3 billion euros. In the consumer business unit, WEPA is the specialist for the private label of European retailers. The Professional business unit, with the brands BlackSatino and Satino by WEPA, stands for sustainable and professional hygiene solutions, which are used in public washrooms, the industry, offices or health care for example. The headquarters of the WEPA Group is in Arnsberg, North Rhine-Westphalia.

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Established in 1978, Gulf Paper Manufacturing was the first company to start manufacturing paper in the Gulf region in 1981. Owned by two families of Kuwaiti entrepreneurs, it operates three production lines at its Mina Abdullah paper mill in Kuwait: PM1 produces packaging grades, mainly Fluting medium, Test liner and white top liner, using 100% recycled paper; PM2 manufactures tissue from 100% virgin pulp; the third is a tissue converting line.

Its current capacity is 70,000 tons, with 70% of its packaging grades being destined for export to GCC (Gulf Cooperation Council) countries and chiefly Saudi Arabia, and the domestic market accounting for approximately 30% of its business.

Established in 1978, Gulf Paper Manufacturing was the first company to start manufacturing paper in the Gulf region in 1981. Owned by two families of Kuwaiti entrepreneurs, it operates three production lines at its Mina Abdullah paper mill in Kuwait: PM1 produces packaging grades, mainly Fluting medium, Test liner and white top liner, using 100% recycled paper; PM2 manufactures tissue from 100% virgin pulp; the third is a tissue converting line.

Its current capacity is 70,000 tons, with 70% of its packaging grades being destined for export to GCC (Gulf Cooperation Council) countries and chiefly Saudi Arabia, and the domestic market accounting for approximately 30% of its business.

In December 2019, Toscotec completed a major rebuild of its PM1 dryer section. We asked Mr. Ghaleb Al Hadhrami, Gulf Paper Manufacturing Projects & Development Manager, to talk about what they achieved with this rebuild.

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Will you please tell us about yourself and your work at Gulf Paper Manufacturing?

I graduated in Paper Technology Engineering in 1981. Two years later, I joined Gulf Paper Manufacturing as a production trainee. In the following years, I held several roles at Gulf Paper until I was promoted Production Manager in 1987. During the Iraqi invasion of Kuwait in 1990, I worked as Production Engineer for Fine Group in Al Bardy Mill, Egypt and then in Nigeria for Bel Papyrus, which operated a Toscotec tissue machine. Finally, in May 1993 I went back to Gulf Paper as Production and Maintenance Manager. In 2003, the company purchased Ameer Paper Mill in Jebel Ali, Dubai. I managed this project as Project Manager first, then as Managing Director, in addition to my responsibilities at our Kuwait factory. Since 2016, I have been holding the position of Projects and Development Manager for both paper mills.

In 2019, Gulf Paper placed an order with Toscotec for a major rebuild of its PM1. What was the reason behind this investment? And why did you select Toscotec?

We had 4 main reasons to invest in this rebuild. First and foremost, we aimed to increase production. Secondly, we wanted to improve the quality of the fluting and test liner we were manufacturing. Thirdly, we wanted to reduce downtime and maintenance costs to a minimum. And finally, we wished to do a major upgrade of PM1 in order to equip it with state-of-the-art technology.

We chose Toscotec because they were the first paper machinery manufacturer to introduce steel dryers, and then steel Yankee dryers, on the market. They have installed TT SteelDryers all over the world and have successfully proven the advantages of this technology compared to cast iron cylinders. At present, they are the supplier with the most extensive experience in the design, manufacturing, operation and maintenance of steel dryers.

Why did you choose Toscotec as your supplier?

We chose Toscotec as supplier of the whole mechanical project because of their good reputation in the market, high equipment quality, their commitment, competitive prices and strict project guarantees. I am extremely satisfied with the format of the supply including the erection from the same company. I would chose it again in the future and I would recommend Toscotec to my contacts in the paper industry.

Focusing on the project, what did you achieve with this rebuild?

First, in terms of time schedule, the machine downtime was implemented precisely according to the GANTT project timetable that Toscotec provided at the beginning. In the end, PM1 was started up ahead of schedule.

Second, in terms of our targets, within two months from start-up, the production increased by 15% and we expect to achieve an increase of over 20% within the next few months after removing the stock preparation bottlenecks we currently have.

Third, the dryer section efficiency we achieved with the new TT SteelDryers and the steam & condensate removal system is higher than we predicted.

Finally, we registered a significant improvement in product quality, particularly in the moisture and basis weight profiles, as well as the final hand feel.

Are you satisfied with the new silent drive configuration?

We are very satisfied with it! PM1 is now running very silently, without noise or vibration.

What about energy efficiency: did you achieve a reduction of your energy consumption?

Yes, after the rebuild, we witnessed a significant reduction of our energy consumption figures. In particular, we cut down the electric power consumption in the drives by 35% and the diesel consumption in the steam boilers by 15%.

How would you describe the cooperation with Toscotec?

Toscotec team proved to be highly skilled and very cooperative. They were very committed throughout the entire project and were able to take fast decisions and come back with responses to our problems. We felt they had a good understanding of our needs and factored those in effectively in planning and follow-up phases.

During the erection, the onsite team was very professional and hardworking. They ensured the completion of commissioning and start-up in time and up to our quality standards. Finally, after start-up, Toscotec supported us to achieve stable operations in a very short time.

We asked Mr. Ghaleb Al Hadhrami, Gulf Paper Manufacturing Projects & Development Manager, to talk about what they achieved with this rebuild.

Will you please tell us about yourself and your work at Gulf Paper Manufacturing?

I graduated in Paper Technology Engineering in 1981. Two years later, I joined Gulf Paper Manufacturing as a production trainee. In the following years, I held several roles at Gulf Paper until I was promoted Production Manager in 1987. During the Iraqi invasion of Kuwait in 1990, I worked as Production Engineer for Fine Group in Al Bardy Mill, Egypt and then in Nigeria for Bel Papyrus, which operated a Toscotec tissue machine. Finally, in May 1993 I went back to Gulf Paper as Production and Maintenance Manager. In 2003, the company purchased Ameer Paper Mill in Jebel Ali, Dubai. I managed this project as Project Manager first, then as Managing Director, in addition to my responsibilities at our Kuwait factory. Since 2016, I have been holding the position of Projects and Development Manager for both paper mills.

In 2019, Gulf Paper placed an order with Toscotec for a major rebuild of its PM1. What was the reason behind this investment? And why did you select Toscotec?

We had 4 main reasons to invest in this rebuild. First and foremost, we aimed to increase production. Secondly, we wanted to improve the quality of the fluting and test liner we were manufacturing. Thirdly, we wanted to reduce downtime and maintenance costs to a minimum. And finally, we wished to do a major upgrade of PM1 in order to equip it with state-of-the-art technology.

We chose Toscotec because they were the first paper machinery manufacturer to introduce steel dryers, and then steel Yankee dryers, on the market. They have installed TT SteelDryers all over the world and have successfully proven the advantages of this technology compared to cast iron cylinders. At present, they are the supplier with the most extensive experience in the design, manufacturing, operation and maintenance of steel dryers.

Why did you choose Toscotec as your supplier?

We chose Toscotec as supplier of the whole mechanical project because of their good reputation in the market, high equipment quality, their commitment, competitive prices and strict project guarantees. I am extremely satisfied with the format of the supply including the erection from the same company. I would chose it again in the future and I would recommend Toscotec to my contacts in the paper industry.

Focusing on the project, what did you achieve with this rebuild?

First, in terms of time schedule, the machine downtime was implemented precisely according to the GANTT project timetable that Toscotec provided at the beginning. In the end, PM1 was started up ahead of schedule.

Second, in terms of our targets, within two months from start-up, the production increased by 15% and we expect to achieve an increase of over 20% within the next few months after removing the stock preparation bottlenecks we currently have.

Third, the dryer section efficiency we achieved with the new TT SteelDryers and the steam & condensate removal system is higher than we predicted.

Finally, we registered a significant improvement in product quality, particularly in the moisture and basis weight profiles, as well as the final hand feel.

Are you satisfied with the new silent drive configuration?

We are very satisfied with it! PM1 is now running very silently, without noise or vibration.

What about energy efficiency: did you achieve a reduction of your energy consumption?

Yes, after the rebuild, we witnessed a significant reduction of our energy consumption figures. In particular, we cut down the electric power consumption in the drives by 35% and the diesel consumption in the steam boilers by 15%.

How would you describe the cooperation with Toscotec?

Toscotec team proved to be highly skilled and very cooperative. They were very committed throughout the entire project and were able to take fast decisions and come back with responses to our problems. We felt they had a good understanding of our needs and factored those in effectively in planning and follow-up phases.

During the erection, the onsite team was very professional and hardworking. They ensured the completion of commissioning and start-up in time and up to our quality standards. Finally, after start-up, Toscotec supported us to achieve stable operations in a very short time.

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The Arab Company For Paper Products Ltd. (Arapepco) successfully started up its PM1 at Khan Al-Asal paper mill, near Aleppo, Syria, after a major rebuild supplied by Toscotec. The paper machine features a reel trim width of 2,850 mm, 800 mpm design speed, and produces fluting and test liner in the range of 105 to 200 gsm using 100% recycled paper. Toscotec carried out a complete rebuild of PM1 from the press section to the pope reel.

Previously, the paper machine was rebuilt by Toscotec in the forming area with the installation of a TT Headbox and modification of the Fourdrinier section, as well as a dryer section rebuild.

The latest rebuild comprises the press section, dryer section and pope reel. The former included the supply of a combi plus jumbo press and a size press. For the dryer section, Toscotec provided its energy-efficient TT SteelDryers featuring 10 bar maximum operating steam pressure, and a tail threading system with air and rope. The supply also included some approach flow system equipment, TT Unirolls, as well as a completely new pope reel and a rewinder unwind stand.

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The targets of the rebuild are to increase PM1 production capacity, to extend the range of products produced and to improve paper quality.

Hasan Badinjki, Chairman of Arab Company for Paper Products Ltd., says, “This project is a miracle. We implemented it during the conflict with Toscotec’s support and it truly required all our efforts to get to today’s result. We upgraded the machine with the latest technology and it is currently performing very well. Arapepco aims to install a top layer in 2021 to meet increasing market demand especially for white top.”

Enrico Raffanti, Toscotec’s P&B Technical Manager, says, “Due to difficult country situation in Syria in the recent past, this project represented a real challenge from many points of view. We continuously supported Arapepco from our headquarters and on site, and finally we carried out a comprehensive rebuild of the existing PM1 into a state-of-the-art paper machine. Such a positive outcome is indeed a source of great satisfaction for both our work teams. I congratulate Arapepco for their strong determination to complete this project successfully.”

About Arab Company for Paper Products Ltd.

Arapepco is a privately owned company established in 1994 by the Badinjki family. It produces paper and cardboard products including fluting, test liner paper, coloured wrapping paper and carton, grey board and formica using 100% recycled fibres. The company employs 160 staff and its production base covers an area of 24,000 sq.m.

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Toscotec is pleased to announce that, following the obtainment of all required regulatory approvals, Voith has successfully completed its acquisition of Toscotec. Toscotec is now part of the Voith Group.

Andreas Endters, President and CEO of Voith Paper, says: “Toscotec’s acquisition matches Voith’s targets of strategic growth in a perfect way. Toscotec’s range of products and services effectively supports our portfolio and further strengthens our position as a full-line supplier in important areas of the paper industry.”

Toscotec will continue to offer its portfolio as established. The company will remain entrepreneurial in nature and will operate under the established Toscotec brand. In the area of tissue, Toscotec will carry out the business with new lines and major rebuilds for the whole Voith Group in the future. Voith Paper will continue to serve its delivered tissue machines. All other business activities will remain unaffected, and Voith and Toscotec customers will be able to purchase via their existing sales channels as usual.

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Alessandro Mennucci, CEO of Toscotec, says: “This acquisition is a landmark in the history of our company. By joining forces with Voith, we plan to pursue new ambitious goals. We will build on our expertise and strong reference base in the paper industry and will be able to offer added value to our customers.”

Established in 1948, Toscotec specializes in the design and manufacture of machinery and equipment for the production of tissue, paper, and board. Headquartered in Lucca, Italy, and with subsidiaries in China and the USA, Toscotec provides its customers with state-of-the-art technologies and customized solutions from complete production lines to rebuilds and single components. Technology Group Voith acquired 90 percent of the shares.

The 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.

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South 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.

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Itzik Nikfard and Rafi Nikfard, Directors of Picknik Marketing Pty Ltd, say, “This project marks a key expansion phase for our company. Due to the success of our SnowSoft brand, we are expanding our presence in the regional market, and are determined to continue on this trend by investing in advanced technology. Toscotec’s machinery will sustain our future growth by delivering the tissue quality and production efficiency we need to succeed in South Africa.”

“We are very happy to have partnered on this new project with Picknik Marketing, who is one of the most important local producers in South Africa”, says Toscotec Area Sales Manager Matteo Giorgio Marrano, “The successful start-up of this line is the result of the close cooperation between our technical teams. Toscotec thus strengthens its position in the South African market, where we successfully installed three complete tissue lines and one major rebuilding project since 2017.”

About Picknik Marketing Pty Ltd

Established in 1999, Picknik Marketing Pty Ltd manufactures high quality tissue products including toilet paper, serviettes, paper towels, facial tissue under the brand SnowSoft and wadding-jumbo rolls.

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From July 2019 to February 2020, Toscotec successfully completed two customized rebuilds at Lucart Diecimo tissue mill. The two rebuilding solutions included the replacement of PM5 and PM6’s existing Yankees with Toscotec’s second-generation Steel Yankee Dryers, complete steam and condensate systems, as well as the installation of a TT SuctionPressRoll.

This is yet again another major achievement in the strong and long-lasting cooperation between Lucart and Toscotec. Over the last ten years, Toscotec supplied to Lucart Group one complete tissue line, two slitter rewinders TT WIND, and various tailor-made rebuilding solutions on six different tissue machines in Italy and France.

The Lucart Group are pioneers in sustainability and they continuously uphold the highest standards of energy efficiency and specific energy consumption in their production processes to promote fair and sustainable development in our shared environment.

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Lucart has tapped Toscotec for its efficient drying solutions, in particular TT SYD and its energy recovery-oriented system design. The extraordinary energy saving advantages that TT SYD delivers, on a potentially infinite number of cycles over the course of its life, save a significant amount of energy and operating costs. Toscotec’s energy recovery equipment, chiefly heat exchangers, are a key part of TT SYD’s steam and condensate system in that they contribute to achieving the highest possible level of thermal energy efficiency.

“Based on the high quality of the work done on PM5 and PM6, Toscotec confirmed its leadership in the construction and installation of steel Yankee dryers. We are very satisfied with the achieved performances, as well as the time schedule and project management of these rebuilds. The work team and the constructive collaboration have been an important key to the success of the projects.” said Eng. Franco Pasquini, Lucart’s Chief Technology Officer.

Valerio Volpi, Toscotec’s Project Manager of Lucart’s PM5 and PM6 rebuilds, says: “Our highly qualified Italian technicians worked with Lucart’s experts as one team. We were right on schedule according to the agreed timetable and the two TT SYDs performed well from the first hours of operation. This is a shared achievement for the Lucart-Toscotec team.”

About Lucart

Lucart, a leading company in Europe in the production of tissue products for daily use (toilet, kitchen, napkins, tablecloths, handkerchiefs etc.), airlaid products, and MG paper was founded in 1953 by the Pasquini Family.

The company's production activities are distributed over 3 Business Units (Business to Business,

Away from Home and Consumer) operating in the development and sales of products with brands such as Tenderly, Tutto, Grazie Natural and Smile (Consumer area), Lucart Professional, Tenderly Professional, Fato and Velo (Away from Home area).

Lucart’s production capacity is 395,000 tonnes/year of paper on 12 continuous machines. Its

consolidated turnover will amount to more than €500 million, with more than 1,500 employees in 9 production plants (five in Italy, one in France, one in Hungary and two in Spain) and a Logistics Centre in Italy. Since 2018, Lucart has been part of the CE100 network, the pre- competitive innovation program designed by the Ellen MacArthur Foundation to give organizations the opportunity to develop new opportunities and achieve their circular economy goals as quickly as possible.

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Toscotec will be at Tissue World Miami 2020 Booth D-20 to showcase its innovative Tissue Technology including the Energy-Savings solutions customized for Sofidel America.

On March 13 at 1:00 pm, Sofidel’s Vice Chief Technical Officer Davide Mainardi and Toscotec’s Sales Director Marco Dalle Piagge will jointly present “Energy Efficient Solutions for Sofidel America: a Case Study”, which offers a detailed analysis of this new integrated tissue mill from a sustainability perspective.

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The presentation will focus on Toscotec’s scope of supply that included Detailed Process Engineering of the plant and layout (“Inside the Box”) to cut energy consumption and ensure top efficiency in the use of thermal and electrical energy. In particular, Toscotec’s design focused on the energy recovery from the Tissue Machine Drying Section and Auxiliary Systems, Process Optimization, as well as on the reduction of water consumption and Virgin Fiber usage.

Toscotec will also take part in the following events of the Tissue World Miami Conference:

On March 10, at 1:00 pm, John Holton, Technical Support Toscotec North America, will moderate the Yankee Dryer Workshop titled “Troubleshooting and Problem Solving” and will deliver a presentation on the subject of “Overview of Yankee Diagnostics”.

On March 11, at 2:10 pm, Toscotec Technical Director Paolo Raffaelli will take part in the Senior Management Symposium’s Panel Discussion “Business Resilience in the '20s: Technological, Liability, and Human Resource Challenges”.

The Toscotec teams of North America and Toscotec Italy will be at Booth D-20 from Wednesday, March 11, through Friday, March 13.

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