Displaying items by tag: Toscotec

Toscotec has successfully started up its 200ᵗʰ Steel Yankee Dryer at César Iglesias Group’s mill in Santo Domingo, Dominican Republic.

César Iglesias Technical Director, Jesús Feris Ferrús, commented: “Following three months of stable operation, we can confirm that our new steel Yankee dryer is delivering exceptional performances. We registered a 25% reduction of our overall thermal consumption including Yankee and Hoods. The TT SYD’s drying capacity is so high that we could significantly decrease the hoods temperature, thereby saving a substantial amount of energy. We also witnessed a great improvement of our tissue quality, in terms of hand feel and CD moisture profile. This led to an increase in our converting efficiency, which we estimate to be in the range of 10%.”

Since the first TT SYD was started up in the year 2000, this breakthrough innovation has come a long way. Toscotec’s TT SYD was the first Yankee dryer made of steel to come to the global market and it has since outclassed cast-iron Yankees to become the new technological standard of the tissue industry. Since then, TT SYD has had numerous imitation attempts, but none has reached its superior level of performance and the service experience which makes Toscotec the leading manufacturer of steel Yankee dryers worldwide.

With over 220 TT SYDs sold around the globe, Toscotec is by many magnitudes the world leading manufacturer of Steel Yankee Dryers; 200 cylinders currently operating all over the world is a notable milestone. These TT SYDs are running efficiently in more than 40 different countries across 5 continents, including over 110 cylinders in Asia and over 50 in Europe. The US market has only recently opened up to steel Yankees, and TT SYD sales have already reached over 10 units.

Out of the top 12 tissue producers in the world, 10 groups have recognised TT SYD’s superior energy efficiency and performance, and installed it at one or more of their production sites. These producers include Essity, APP, Hengan, Sofidel, WEPA, CMPC, Kruger and others who remain confidential.

Last year, Toscotec’s research and development launched the TT SYD’s third generation design. The first and second generation had been developed and continuously improved in 20 years of ongoing research, monitoring, and service of steel Yankees operating under very different conditions all across the globe. This accumulated expertise allowed for the development of TT SYD’s third product upgrade, where the height, width, and pitch of the internal ribs, as well as the shell thickness, attain an optimal geometry to maximize heat transfer efficiency without compromising safety or longevity. Toscotec’s R&D is also focusing on new innovations, including the Defender®, an internal surface treatment that ensures extraordinary resistance against corrosion and erosion. TT SYD’s operation stability, durability, and correct safety coefficient are all guarantees of its safety.

Moreover, in order to optimize the manufacturing process and shorten the delivery period, in 2012 Toscotec set up a manufacturing space specifically dedicated to the construction of its Steel Yankee Dryers. TT SYD Technology Lab is a highly technological and fully integrated 5,000 sqm plant, located just a few kilometers away from Massa’s maritime port, offering the logistical advantage of ensuring easy access to the seaport for large diameter Yankees.

Finally, beside TT SYD design advancements, Toscotec Service team has progressively and continuously upgraded the quality and accuracy of its Yankee dryer services, by relying on Toscotec’s extensive experience - the longest in the tissue industry - of steel Yankee engineering design, manufacturing, and service, in order to achieve optimal performance and infinite life.

Papeterie Le Bourray selected Toscotec to rebuild its PM4 tissue machine at Saint-Mars-la-Brière, near Le Mans, France. The start-up is scheduled for mid-2020.

The rebuild scope includes the modification of the existing Approach Flow System with a new fan pump and a fully hydraulic TT Headbox designed to operate in Tisco Former configuration, but capable of being upgraded into Crescent Former configuration in the future. Toscotec will provide full beginning to end support consisting of the detailed engineering, dismantling of the existing components, and installation of new components, commissioning, start-up supervision, and training. The estimated overall shutdown time will be less than a week.

The target of the rebuild is to improve sheet formation quality and CD basis weight profile, as well as increasing the machine speed. The tissue line is dedicated to the production of towel tissue using chemical pulp and waste paper.

Francois Bourdin, CEO of Papeterie Le Bourray, says, “We are glad to work with Toscotec, who is a leader in the manufacture of tissue machines. This headbox is our first major project since we restarted the mill in April 2019, and it will allow us to improve our quality and seek new markets.

Riccardo Gennai, Toscotec Sales Manager for Europe, says, “We are glad to have been selected as the supplier of this important rebuilding project. Toscotec is well positioned in Western Europe for new projects, but also for major rebuilds, which require a high degree of customization and flexibility, as well as a very tight schedule, where you coordinate all aspects of the project in order to reduce the machine downtime to a minimum. Over the last ten years, we completed more than 20 rebuilds in Western Europe.”

For further information, please contact:

Marco Dalle Piagge, Sales Director, Toscotec Tissue division, This email address is being protected from spambots. You need JavaScript enabled to view it.

Riccardo Gennai, Sales Manager, Toscotec Tissue division, This email address is being protected from spambots. You need JavaScript enabled to view it.

The TADVISION^® machine supplied by Toscotec on a turnkey basis to Essity Mexico started up at its tissue mill, in Ciudad Sahagun, Hidalgo. 

Designed for extra-premium product quality and superior energy efficiency, the TAD machine is equipped with a Steel Yankee Dryer, a successful pioneering innovation on this technology.

Toscotec’s turnkey supply includes stock preparation, vacuum plant, complete electrification, extensive automation package, and all necessary auxiliary systems.

Toscotec also provided a skilful service package including detailed engineering, complete erection, commissioning, test runs, and start-up assistance supporting the vertical start-up of the TADVISION^® machine.

Roberto Caballero, Vice-president Manufacturing Essity Latin America, says: “With our first TAD machine at Essity Mexico, we aim to increase the pace of innovation to deliver premium and more environmentally sound products to our customers and consumers in the region”.

Marco Dalle Piagge, Toscotec Sales Director, says, “The new TADVISION^® machine is state of the art designed for efficient air-through drying. We are happy to see that the mill is achieving very good results both in terms of machine efficiency and of energy consumptions.”

Since 2006, German tissue manufacturer WEPA Group has chosen Toscotec for all its hood rebuilds at various paper mills in Germany and Italy. These projects were all turnkey operations, where Toscotec supplied the complete package for the rebuild, from its engineering design, to the components supply, down to onsite dismantling operations, erection, commissioning and start-up. For these rebuilds, Toscotec developed a custom-made design of its hoods aimed to increase production and reduce energy consumption to a minimum; it engineered the nozzle boxes and customized the air system according to WEPA’s requirements, in order to achieve top operation flexibility in cross direction moisture control and better machine runnability. Overall, Toscotec supplied other hood and air systems to WEPA in Germany, France and Poland as part of the supply of new tissue lines. The following three projects are a selection of the rebuilds carried out from 2006 to 2019.  

WEPA Marsberg-Giershagen PM5 drying section rebuild.

WEPA chose Toscotec for 7 custom-made hood and air system rebuilds on a turnkey basis. In 2006, WEPA Marsberg-Giershagen mill in Germany invested in the rebuild of the drying section of its PM5 and selected Toscotec for the supply of high-temperature hoods and its Steel Yankee Dryer TT SYD-15FT. WEPA believed in this new technology at a time when Toscotec had only manufactured a few TT SYD, and its innovative steel design had only just been introduced into what was a cast iron-dominated tissue market back then. Thirteen years later, WEPA has successfully installed another 6 TT SYDs and Toscotec has developed and implemented three successive product generations and sold over 220 steel Yankees worldwide, including 5,600 mm width and 22 ft diameter TT SYDs. WEPA’s foresight was proved right, for steel Yankees are now recognized as the new technological standard in the tissue industry at a global level.

The gas-fired hoods supplied to WEPA Marsberg-Giershagen in 2006 operate at 600-650°C and are equipped with low emission burners running on high-temperature combustion air. The energy necessary to heat up the combustion air is recovered from the air system itself through the use of heat exchangers. As a result, the advantage of low emission burners is twofold: one is the reduction of air pollutants such as nitrogen oxides (NOx) and carbon oxide (CO), and the second is cutting the overall gas consumption. 

WEPA Italia Cassino PM13 drying section rebuild.

In 2013, Toscotec supplied a hood rebuild to WEPA Italia Cassino in southern Italy. The German Group confirmed the Italian supplier as the turnkey supplier of its second hood rebuild based on the advantages of Toscotec’s technical proposal. 

Firstly, the project was completed according to schedule, in a record time of only 6 months from contract signature to start-up. Secondly, the engineering design was custom-made based not only on the machine specifications, but also on the installation logistics, in order to avoid opening up the roof of the machine building and renting external crane equipment. Toscotec designed and manufactured these double-width hoods in separate modules and consequently achieved a significant reduction of the installation time and costs. According to WEPA’s needs, in order to reduce machine down time and speed up the mill’s administrative procedures, Toscotec realized a particular layout where the air system was installed outside the building. 

The Dominican Group César Iglesias successfully started up a second generation TT SYD at its paper mill in Santo Domingo. Following start-up, the mill has observed a marked increase of production capacity and important energy savings in the drying section. 

Thanks to continuous R&D on Toscotec’s Steel Yankee Dryer, the height, width and pitch of the internal ribs as well as the shell thickness achieved an optimal geometry, which guarantees a highly efficient heat transfer. The supply also includes the steam and condensate system, the Yankee coating spray boom, a new forming roll, as well as the complete overhaul service of press rolls. 

In response to the customer’s request for the fastest possible delivery, Toscotec further refined the production time and was able to deliver the Steel Yankee Dryer in record time. Since the opening of Massa Technology Lab in 2016, an integrated plant dedicated to the production of Steel Yankee Dryers, Toscotec has sought to optimize the manufacturing process of its TT SYD and shortened their delivery period. 

Jesús Feris Ferrús, César Iglesias Technical Director, says, “When we selected the supplier for this investment, we thought that the TT SYD’s superior performance and short delivery time made it the most competitive choice in the market. This was our first cooperation with Toscotec and we have been positively impressed by their technical and project management team. The energy efficiency of the TT SYD will allow us to reduce the manufacturing cost of our tissue line and give us a competitive advantage in the market.”

Simone Pieruccini, Toscotec’s Pressure Vessel Technical Manager, says, “As soon as we understood the customer’s need for a fast delivery, we rearranged the production schedule, in order to reduce the construction time as much as we could. From a technical point of view, we were in tune with César Iglesias’ team, which made our first cooperation very easy for everybody.”

The César Iglesias Group thus enters the tissue market, starting the production and converting of toilet tissue, paper towels and napkins. 

JSC "Yarpaper" selected Toscotec for a major rebuild of its paper machine at Yaroslavl mill, northeast of Moscow, Russia. PM1 has a wire sheet width of 2,830 mm, produces test liner and fluting in the range of 100 to 150 gsm, using 100% waste paper. 

Toscotec will supply the approach flow system, including screens, fan pumps, TT Headbox-H fitted with dilution control system and a newly designed Fourdrinier make up. The sheet path in the press section will be optimized, including the sheet transfer to the dryer section. 

Toscotec will supply a new complete dryer section, with 35 TT SteelDryers designed to operate at 10 barg, along with framing, canvas rolls, doctors, stabilization boxes, stretchers, guiding and tail threading system and the mechanical drives for the entire paper machine. 

The scope also includes the engineering, erection supervision, commissioning, start-up assistance and training.

(from right to left:) Mr. Sergey Dotsenko, Chairman of the Board of Directors of JSC "Yarpaper" and Mr. Alessandro Mennucci, CEO of Toscotec.

This major rebuilding project will modify the entire paper machine, including the approach flow system and sets ambitious targets of production increase and quality improvement, maintaining the same PM length, thereby reducing the impact on the existing building. 

Chairman of the Board of Directors of JSC "Yarpaper", Mr. Sergey Dotsenko, says, “This operation represents a strategic investment aimed to improve product quality, increase our production output and efficiency. As an FSC-certified manufacturer, we are focused on the sustainability of our operations. After the joint evaluation of the project, we selected Toscotec because of their understanding of our needs and development of the best technical solution in order to increase the process and drying efficiency of PM1. This is in step with boosting its capacity and expanding the product range from 90 to 160 gsm. The rebuild will be in line with our environmental standards.” 

Toscotec’s Head of Sales Application Gian Luca Fornesi says, “This is our first important paper & board project in Russia. Thanks to the support of Pulp & Paper Processes, Ltd., we are glad to enter the Russian market with such a recognised producer and such an extensive rebuild, which spans from the approach flow to the wet section of the paper machine, down to the dryer section. Most sections will be newly designed, or extensively rebuilt, to achieve a substantial production increase. During the project evaluation, we assessed a number of possible solutions for the customer and we are confident that our rebuild will eliminate the main bottlenecks of this production line.”