Toscotec will deliver three tissue machine rebuilds located at different mills to a confidential global producer.
Toscotec will rebuild the drying sections of two tissue machines, as well as the wet end and winding sections of another machine. The drying section rebuilds include the supply of two Toscotec’s third-generation-design TT SYD Steel Yankee Dryers, steam and condensate systems, and high efficiency TT Hoods, including one newly optimized combustion system. The energy efficiency given by the integration of the steel Yankee and the hoods will result in a significant reduction of the tissue machines’ thermal consumption.
The other project requires the modification of the approach flow and fiber recovery systems and the complete rebuild of the machine’s wire and pope reel sections.
The provision of expert services, including engineering, dismantling of old equipment, erection, commissioning, start-up, and training, ensures a complete package for the rebuilds.
Since the start-up of its first TT SYD in 2000, Toscotec is the forerunner and world leading manufacturer of Steel Yankee Dryers boasting close to 230 TT SYDs sold and over 200 currently operating in five continents.
These two new TT SYDs will replace the mills’ existing Yankee dryers. Toscotec holds the record as the manufacturer who supplied all of the SYD replacements that took place in Europe to date.
Riccardo Gennai, Toscotec Sales Manager, says: “We take pride in the continuous evolution of TT SYD. Toscotec started up the first steel Yankee dryer in the tissue industry. TT SYD’s third-generation design enhances the machine’s drying performance and energy efficiency to a degree that it really makes us stand out in the market.”
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Last year, Mondi, a leading global packaging and paper manufacturer, announced that it would expand its existing plant in Ansbach, Southern Germany, to become the largest heavy-duty corrugated cardboard plant in Europe. The “Ansbach 2020” project, an investment worth €30 million, is in its final stages of completion and is meeting its customers' needs with innovative sustainable packaging solutions.
- €30 million investment expands product portfolio and improves processes
- Successful installation of state of the art machinery for optimised operations
- Broader range of corrugated solutions for more specialised and sustainable customer uses
The plant successfully installed state of the art machinery, including a new corrugator, die-cutting-machine, inline-machine, paper storage, shipping facility, waste processing facility and intralogistics system. The investment is strengthening the plants position as the go-to-expert for innovative and sustainable packaging solutions in the region. Furthermore, the updated machinery results in less energy consumption and reduces the carbon footprint of the plant.
“With this investment we have been able to broaden our sector expertise offering to include not only the automotive sectors but also expand into the the construction supply, sports and leisure industry, delivering quality sustainable packaging goods,” says Markus Skiba, Managing Director, Mondi Wellpappe Ansbach.
The improvements delivered by this investment include:
- Increased production capacity, leading to shorter delivery times to customers
- Broader range of corrugated solutions for more specialised customer uses
- Enhanced product quality
The investment also includes a Customer Innovation Centre, which will offer facilities for workshops, product development, optimisation and product presentations.This hub will lead to further innovation and testing of packaging solutions to reduce their enviornmental impact and will mark the project completion in 2021.
Mondi Wellpappe Ansbach is the home of award-winning packaging solutions. In 2020, the plant developed two ScanStar award-winning transportation packaging solutions for Volvo. The team works closely with its automotive industry customers to create value-added corrugated solutions that protect heavy-duty goods such as brake boosters and headlamps, while improving processes and logistics. The ScanStar jury especially highlighted the factors cost-effectiveness, sustainability, stability and improvement in work ergonomics.
About Mondi Corrugated Solutions
Mondi Corrugated Solutions, a segment of the business unit Mondi Corrugated Packaging, is a leading supplier of corrugated packaging in Europe, with strong focus on Central and South-East Europe. In 2020 the business won three WorldStar awards, in 2019 the business won seven WorldStar Awards for innovation, to add to five won in 2018, more than any other company worldwide. Through a network of 16 plants Mondi Corrugated Packaging provides innovative design and state-of-the-art printing and gluing technology. The packaging types range from standard transit cases and heavy duty containers to upscale consumer displays. They are applied as shelf- or retail-ready solutions, transport cases or large containers when shipping FMCG's, perishables, industrial and dangerous goods as well as other products.
Mondi is a global leader in packaging and paper, contributing to a better world by making innovative packaging and paper solutions that are sustainable by design. Our business is fully integrated across the value chain – from managing forests and producing pulp, paper and plastic films to developing and manufacturing effective industrial and consumer packaging solutions. Sustainability is at the centre of our strategy and intrinsic in the way we do business. We lead the industry with our customer- centric approach, EcoSolutions, where we ask the right questions to find the most sustainable solution. In 2019, Mondi had revenues of €7.27 billion and underlying EBITDA of €1.66 billion.
Mondi has a premium listing on the London Stock Exchange (MNDI), and a secondary listing on the JSE Limited (MNP). Mondi is a FTSE 100 constituent, and has been included in the FTSE4Good Index Series since 2008 and the FTSE/JSE Responsible Investment Index Series since 2007.
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.
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.
Step change for modern mill transformation as new online measurement enables more efficient and cost-effective management of start-up events
ABB has just launched Weight Virtual Measurement, an ABB Ability™ Performance Service that allows paper, packaging and tissue manufacturers to recover quickly from sheet breaks. It works by reducing the amount of off-spec paper produced directly after sheet breaks and during the subsequent start-up period, potentially saving thousands of dollars each year.
The new digital solution uses inputs that affect product weight - such as stock flow, consistency, first pass retention and machine speed - to provide an online conditioned weight measurement during a sheet break event when the Quality Control System (QCS) weight sensor cannot provide a measurement since there is no paper to be measured.
By providing operators with a continuously optimized, machine-learning generated measurement model, or ‘soft sensor’, Weight Virtual Measurement helps reduce downtime, improve grade change times and decrease the time to achieve on-spec paper. Operator displays combine various inputs and highlight when the Virtual Measurement is available in the absence of the QCS measurement. Operators can view the current status and work with a choice of adjustments to get back on target.
“Our new Weight Virtual Measurement solution is unlike any other in that it combines deep industry expertise with advanced analytics, machine-learning technologies, proprietary modelling and auto-calibration techniques to create an accurate and robust virtual sensor,” said John Schroeder, Global Product Manager for ABB Ability™ applications for pulp and paper. “This will enable mills to make more strategic decisions such as balancing the cost options of getting their production up and running faster versus delaying putting the paper on the reel to avoid compromising their paper quality.”
Weight Virtual Measurement joins the ABB Ability™ Performance Service suite that includes other Virtual Measurement features for pulp and paper mills, all of which do not require an ABB DCS or QCS for implementation. It is delivered via ABB Ability™ Collaborative Operations, a service delivery model that connects production, headquarters and ABB personnel with remote access to ABB digital technologies, data analytics and domain expertise, and incorporates ongoing performance monitoring and analysis of the online calculated weight.
For more information about the solution go to: https://new.abb.com/pulp-paper/abb-in-pulp-and-paper/service/advanced-services/performance-services-for-paper-mills/weight-virtual-measurement
ABB is a trusted partner and leading supplier to the pulp and paper industry, offering deep expertise and a comprehensive portfolio of integrated digital solutions, automation and electrification systems, industry-focused products and comprehensive services to help our customers optimize all phases of the papermaking process. We are committed to serving packaging, paper, tissue and pulp producers to help drive availability, performance, cost and quality improvements. Active worldwide, ABB has over 1,000 pulp and paper professionals who serve customers in over 50 countries. www.abb.com/pulpandpaper
ABB (ABBN: SIX Swiss Ex) is a leading global technology company that energizes the transformation of society and industry to achieve a more productive, sustainable future. By connecting software to its electrification, robotics, automation and motion portfolio, ABB pushes the boundaries of technology to drive performance to new levels. With a history of excellence stretching back more than 130 years, ABB’s success is driven by about 110,000 talented employees in over 100 countries. www.abb.com
Wepa Group is one of the largest tissue manufacturers in Europe, with 13 sites, 21 paper machines, a production of approx. 780,000 t/year, and a positive annual growth trend. Since 2002, Toscotec and Wepa’s cooperation has been particularly strong at Wepa Marsberg-Giershagen, where Toscotec supplied a new tissue line on a turnkey basis, completely rebuilt PM 5 in two different steps and installed new hoods on other two existing machines, with the result that all tissue machines at the mill are now equipped with TT Hoods.
PM 4 and PM 7 Hood rebuilds: Consumption reduction & Speed increase
In order to evaluate the return on the investment, it is always interesting to compare the efficiency of the equipment – consumption and performance - before and after the rebuild. This comparison is particularly clear if we look at PM 4 and PM 7, where the modification involved only the hoods and the air system. After the installation of TT Hood on PM 4, the mill achieved a 12.5% reduction in gas consumption and 50mpm increase in machine speed. The results on PM 7 were similar, with a 13.3% reduction in gas consumption and 50mpm increase in speed.
In general terms, for a tissue machine that produces 30,000 t/y with a thermal consumption of 1.3MWh/t, 10% of drying energy savings equals a cost reduction of approximately 4 €/t, i.e. 120,000 €/y. Additional savings coming from electrical load reduction and machine speed increase must also be considered.
The above figures offer a clear picture of the potential benefits coming from the use of fully updated equipment including state-of-the-art devices dedicated to:
- Energy saving: complete heat recovery chains for steam generation, air and water heating
- Hoods regulation: automatic balancing system
- Pollutants control: burner management system, burner control and fine-tuning
TT Hoods: customized technology for the highest reliability
TT Hoods are entirely custom-made, in order to meet the needs of the paper machine. At WEPA Giershagen, Toscotec calculated the best combination of the open area, hole diameter, and hole pattern to achieve top performance and efficiency.
TT Hoods are designed and manufactured at Toscotec’s headquarters in Lucca, where its engineers and workers have more than 20 years of experience in hoods and air systems. This expertise guarantees the reliability and the constant improvement of their design and performances.
The art of project management in rebuild projects
Finally, time schedule is always essential in rebuild activities. Wepa Giershagen required Toscotec to schedule every phase of the project, allocating the right resources and time, in order to guarantee an accurate paper-to-paper machine shutdown period. On Wepa Giershagen PM 7 for example, the scheduled paper-to-paper shutdown was of 360 hours. The entire work was completed and tested in only 332 hours, i.e. 28 hours ahead of schedule.
Stora Enso has decided to commence a feasibility study and environmental permit application process on enhancing and expanding the pulp- and board-making capabilities at its Skoghall Mill in Sweden. The investment would leverage the already strong mill into an integrated, highly cost-competitive and environmentally-friendly producer of packaging board and bleached softwood market pulp. The investment would serve customers globally and further establish Stora Enso as a provider of high-quality, renewable packaging materials.
The feasibility study will evaluate a possible upgrade and expansion of existing integrated pulp capacity from 370 000 tonnes to 780 000 tonnes annually and a possible increase of 120 000 tonnes in board capacity. After the investment, the mill would be integrated close to 100%, with an additional 220 000 tonnes of softwood market pulp. This would enable a further increase in cost-competitive board production. The project would also significantly lower the fossil CO2 emissions of production. The findings of a recently completed pre-feasibility study supported continuation of the investment process.
If the investment is approved following the feasibility study and environmental permit application process, the capital expenditure for the upgrade and expansion is estimated to be approximately EUR 800–850 million. The feasibility study is expected to be completed by the end of 2021. Production would start earliest in Q4/2023. Currently, Skoghall Mill has an annual production capacity of 885 000 tonnes of packaging board.
“Skoghall Mill is one of our core integrated platforms for packaging materials. The investment would allow us to grow and be more flexible in serving our customers and meet an increasing demand for sustainable packaging among consumers. The investment would be in line with our strategy to accelerate growth in the packaging business as well as to develop the competitiveness of our mills based on economies of scale and integration benefits. It would also bolster the potential of profitable growth in attractive packaging end-use segments, such as liquid packaging board and coated unbleached kraft. The possible decision regarding an expansion of Skoghall Mill will be made once the feasibility study has been completed and pending the outcome of the environmental permit application process with local authorities,” says Hannu Kasurinen, EVP, Stora Enso’s Packaging Materials division.
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Part of the bioeconomy, Stora Enso is a leading global provider of renewable solutions in packaging, biomaterials, wooden constructions and paper. We believe that everything that is made from fossil-based materials today can be made from a tree tomorrow. Stora Enso has some 25 000 employees in over 30 countries. Our sales in 2019 were EUR 10.1 billion. Stora Enso shares are listed on Nasdaq Helsinki (STEAV, STERV) and Nasdaq Stockholm (STE A, STE R). In addition, the shares are traded in the USA as ADRs (SEOAY). storaenso.com
Accelerated by recent events, e-commerce sales continue to boom as today’s consumers purchase more of the products they use every day online — from the clothes they wear to the meals they eat. Unfortunately, this has increased concerns about unnecessary packaging waste and ever-greater levels of plastic pollution. Enter the paper freezer pack, which may one day replace plastic freezer packs for use in shipping refrigerated products.
A Better Way To Chill
While great strides have been made to reduce the environmental burden of e-commerce packaging over the years, the traditional freezer pack remains both a pain point for meal kit customers and an area ripe for innovation.
Domtar’s Catapult team, which includes individuals from market development and new technology innovation process, focuses on uncovering, tracking and evaluating the attractiveness of emerging market opportunities. The team recently revealed its paper freezer pack, an internally-developed potential solution to the issues posed by conventional cold chain offerings. Not only does the pack reduce plastic use, but it also capitalizes on mounting public interest in products made from sustainable wood fiber.
The majority of this revolutionary paper freezer pack is made of forest-derived fiber, including paper, tissue and fluff pulp. It also includes a small amount of superabsorbent polymer, which absorbs and retain water that, once frozen, provides cooling properties.
Innovative Paper Freezer Pack Captures Attention
“Paper freezer pack technology is but one example of several promising projects that the Catapult team is involved in related to innovative fiber-based processes and products,” says Brian Ranson, Domtar’s director of technology innovation.
In fact, this technology is so unique that it was recently named a finalist for the prestigious Sustainable Packaging Coalition (SPC) Innovator Awards. When announcing the finalists, the packaging collaborative said it was impressed by the paper freezer pack’s innovative use of fiber in a growing category while also challenging preconceived notions of what’s possible with paper packaging.
Our preliminary in-house testing has shown that our paper freezer pack technology:
- Can hold its temperature similar to conventional options at a lighter weight
- Demonstrates no leakage
- Exhibits minimal condensation versus conventional packs
Rather than manufacture and convert the paper freezer packs internally, we are in active conversations with leading e-commerce solutions providers that are seeking to capture the value of this patent-pending technology while sourcing more of their packaging from a renewable resource.
“By utilizing market research to develop insights and deepen end-user understanding, Domtar realizes that it can better satisfy current customers while at the same time ‘testing the waters’ with innovative new ones,” says Katie Zorn, director of strategic planning and market development.
Learn more about our paper freezer pack and its innovative use of responsibly sourced wood fiber:
W22 Magnet brings more productivity for the production of paper and pulp
Continuously investing in innovation, WEG's philosophy is to develop high performance products and efficient solutions in order to offer ideal solutions to its customers. Among them is Klabin, the largest producer and exporter of packaging paper in Brazil.
More efficient motor in the lime furnace
Aiming at ensuring better results for its production process, Klabin purchased a 125 HP WEG W22 Magnet motor in October 2019 to replace the DC drive of the lime furnace.
The lime furnace burns the lime mud generated in the pulp production process and turns it into lime, used in the production of the white liquor, which in turn is used for cooking wood in the digester and for making pulp. As this machinery requires attention from the maintenance teams, DC motors are not usually the preferred option due to the high inertia of the load at the start and in operation. However, the change was carried out successfully and the motor has obtained excellent performance rates.
W22 Magnet: the best performance rate on the market
The high efficiency W22 Magnet motors have permanent magnets, thus ensuring advantages such as robustness, high performance and higher power density per frame. Driven by WEG CFW11 frequency inverter, they provide constant torque and a wide speed range, operating even at low speeds with efficiency levels above induction motors, without requiring forced ventilation. Ideal to drive paper machines, replace DC drives and solve applications where speed variation is required.
More energy efficiency for the paper and pulp industry
Energy efficiency cases like this, which promote the replacement of DC motors with high efficiency permanent magnet motors, prove that the return on investment makes good business sense, both in the application and in the selection and acquisition of the equipment, which makes them saving both money and energy in challenging times.
For Klabin, this acquisition enabled greater productivity due to the increase in the machine availability and the equipment energy efficiency. According to analysis made since the motor acquisition in October 2019, there has also been a reduction in energy consumption, exceeding the project expectations.
WEG, recognized for its energy efficiency solutions for various industrial applications, offers the market several combinations of high performance products to bring more innovation and technology for industrial processes worldwide, building solid relationships with large companies such as Klabin.
Klabin is the largest producer and exporter of packaging paper in Brazil. It is the only company in the country to offer the market a solution in short fiber, long fiber and fluff pulps and the leader on the corrugated fiberboard packaging and industrial bag markets. Founded in 1899, it has 18 business units in Brazil and one in Argentina.
The entire management of the company is oriented towards Sustainable Development, seeking integrated and responsible growth, which combines profitability, social development and environmental commitment. Klabin has been part of the B3 Corporate Sustainability Index (ISE) since 2014. It also signed the UN Global Compact and the National Pact to Eradicate Slave Labor, seeking suppliers and business partners who follow the same values of ethics, transparency and respect for the principles of sustainability.
Learn more at: www.klabin.com.br
Founded in 1961, WEG is a global electric-electronic equipment company, operating mainly in the capital goods sector with solutions in electric machines, automation and paints for several sectors, including infrastructure, steel, pulp and paper, oil and gas, mining, among many others. WEG stands out in innovation by constantly developing solutions to meet the major trends in energy efficiency, renewable energy and electric mobility. With manufacturing units in 12 countries and present in more than 135 countries, the company has more than 31,000 employees worldwide. WEG’s net revenue reached R$ 13.3 billion in 2019, 58% from external markets.
Skjern Paper is Denmark’s only paper mill. Founded in 1965, it is situated in Skjern, West Jutland. Since 2005, the ownership majority has been held by Buur Invest A/S, a Danish privately-owned investment company. The mill’s current annual capacity is 75,000 tonnes, including a range of products - coreboard, grey and blueliner, greyboard and sheets - produced from 100% recycled fibres. Skjern Paper is strongly export-oriented, with over 90% of its production sold to packaging and paper businesses in Europe.
In the third quarter of 2019, Toscotec carried out a complete rebuild of its PM1 dryer section, delivering 19 TT SteelDryers. The scope of supply was on a turnkey basis, including dismantling operations, erection, commissioning and start-up. In this interview, Kurt Larsen, Project Engineer at Skjern Paper, shares his views on the main aspects of the rebuild and his overall evaluation.
In 2019, Skjern Paper selected Toscotec to rebuild its PM1. Why did you decide to make this investment? And why did you choose Toscotec?
The main driver for the investment was the need to increase our dryer capacity. PM1 started producing at Skjern in 1967, but it was a second-hand machine, and some of its cast iron dryers dated back to the mid-1940s, some even all the way back to 1927! In order to overcome our drying capacity limits, we decided to install steel cylinders of bigger diameter, operating at a much higher steam pressure (10 barg), new frame and drives that could reach a higher speed. Toscotec’s new dryer section can achieve 800 m/min, which is double the maximum speed we had before.
Secondly, we chose steel dryers against cast iron, because of their higher heat transfer efficiency and better safety. In terms of safety, steel cans are definitely a much better choice.
Among the suppliers we evaluated, Toscotec proved to have the most substantial experience in the design, manufacturing, operation and maintenance of steel dryers. TT SteelDryers have an incredible number of references around the world and they are manufactured internally by Toscotec. This meant we could have one single supplier for the whole dryer section, which solves the problem of grey zones in-between different manufacturers, which would save us a lot of headaches in the end. Skjern considered this aspect a great added value.
Focusing on the rebuild itself, was the project delivered on schedule? How do you evaluate its overall management?
The project was completed on schedule. Other prospective suppliers had foreseen a much longer shutdown period, but Toscotec implemented the whole rebuild within a shutdown period of only 11 days, including dismantling the old equipment and erection of the new dryer section and hood. This timeline was key for us, because bringing the production to a complete stop makes it tough for us to be the flexible supplier we want to be.
Overall, the project management was very well executed. We had committed and competent people at our disposal, and we got all the support we needed on time.
What have you achieved with this rebuild?
First of all, we have registered a production increase of more than 11% so far, but we expect to achieve even more after removing the bottlenecks we still have in the wet-end and press section. Secondly, the rebuild lifted the speed limit we had, allowing us to increase the machine speed, particularly for lower grammages.
What can you tell us about the erection, commissioning and start-up?
The erection was very efficient. We were working 24/7 under safe conditions, without any injuries. Start-up went very smoothly, with a delay of only one day, which was not caused by Toscotec. We are very satisfied with the onsite implementation of the rebuild.
How would you describe the cooperation with Toscotec?
We had very good cooperation with Toscotec. They were attentive to our needs and committed to meet them in the best possible way. If during the erection we had an extra job for them to do or they needed something from us, we helped each other, so that the work was flowing really well. They proved to be very flexible and cooperative. For example, they lent out several people for a few days to help finish up some pipe work. They were working with us towards a shared objective and did not back out when we needed extra help. This is very important to a small mill such as ours, because we have limited resources and therefore we appreciate a supplier who is prepared to go the extra mile to get the job done.
International technology Group ANDRITZ has received an order from ITC Paperboards and Specialty Papers Division (ITC-PSPD) to supply a new evaporation plant for its Bhadrachalam unit located in Telangana, India.
ANDRITZ will supply a new 7-effect evaporation plant on EPC basis with a capacity of 390 t/h that will concentrate kraft black liquor to a final dry solids content of 75%. The plant will be the largest in India and have the capability to improve the quality of condensate from the existing mill so that it can be re-used effectively in the mill and also to reduce water consumption.
ANDRITZ’s lamella technology in the evaporators ensures the desired steam economy at all times, reduces energy consumption by circulation pumps, as well as providing higher black liquor concentration and stability, thus leading to increased and stabilized power production in the recovery boiler. The technology also delivers optimized vapor condensate quality that contributes towards a reduction in the mill’s operating costs. In addition, fewer and shorter washing cycles will enhance overall availability.
This investment is part of ITC-PSPD’s recovery plant modernization project to further strengthen its market position in the paperboard and specialty paper segment.
ITC-PSPD is one of the largest manufacturers of packaging and graphic boards in Southern Asia. The company’s Bhadrachalam unit produces value-added folding boxboard.
International technology group ANDRITZ offers a broad portfolio of innovative plants, equipment, systems and services for the pulp and paper industry, the hydropower sector, the metals processing and forming industry, pumps, solid/liquid separation in the municipal and industrial sectors, as well as animal feed and biomass pelleting. The global product and service portfolio is rounded off with plants for power generation, recycling, the production of nonwovens and panelboard, as well as automation and digital solutions offered under the brand name of Metris. The publicly listed group today has around 27,800 employees and more than 280 locations in over 40 countries.
ANDRITZ PULP & PAPER
ANDRITZ Pulp & Paper provides equipment, systems, complete plants and services for the production of all types of pulp, paper, board and tissue. The technologies and services focus on maximum utilization of raw materials, increased production efficiency and sustainability as well as lower overall operating costs. Boilers for power production, flue gas cleaning plants, plants for the production of nonwovens and panelboard (MDF), as well as recycling and shredding solutions for various waste materials also form a part of this business area.