Displaying items by tag: Toscotec
Toscotec successfully started up a TT SYD Steel Yankee Dryer at Cartiera Ponte d'Oro Ansalcarta in Villa Basilica, Italy. The new Yankee replaced an existing cast iron dryer installed on PM1 in 1993 by Officine Meccaniche Toschi, which was renamed Toscotec in 2003.
Manufactured at Toscotec’s fully integrated TT SYD Technology Center in Massa (Italy), the steel Yankee dryer included the condensate removal system, Toscotec’s patented heads insulation for maximum thermal energy efficiency, as well as expert services from detailed engineering to erection supervision and start-up assistance.
Toscotec is constantly building on its experience of steel Yankee dryers to advance the progress of TT SYD’s design and services. It currently has more than 200 TT SYD operating under the most diverse conditions around the globe, which provide valuable data for further product improvement. This year, Toscotec also introduced TT Defender®, a breakthrough patented innovation that provides Yankees with an internal protection coating against corrosive steam.
Armando Ansaldi, CEO of Cartiera Ponte d'Oro Ansalcarta, says, “We have known Toscotec for many years, and we trust their technology and professional services. This Yankee rebuild is part of our long-term strategy to green manufacturing and achieving the lowest possible carbon footprint using the most advanced technology. With the installation of TT SYD, we aim to significantly boost our energy efficiency in the most energy-intensive section of the paper machine.”
Riccardo Gennai, Toscotec’s Sales Manager, says, “We are very happy to renew our partnership with Cartiera Ponte d'Oro. We are confident that TT SYD will deliver the superior drying capacity that they expect and guarantee substantial energy savings, in line with their objectives.”
About Cartiera Ponte d'Oro Ansalcarta S.r.l.
Founded in 1961 in the heart of Lucca’s tissue paper district, Cartiera Ponte d’Oro Ansalcarta produces rolls of white and coloured tissue paper from almost entirely recycled fibres, for both at home and AfH markets. The Chamber of Commerce of Lucca has acknowledged the historical origins of the paper mill, dating back to 1892, and the history of the founding family of Ansaldi who in 1650 brought the art of paper making to Pescia, in the province of Lucca.
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Toscotec will supply an AHEAD 2.2L tissue line on a turnkey basis to Vajda Papír at its Dunaföldvár mill, near Budapest, Hungary. The start-up is planned for the first half of 2022.
The new AHEAD 2.2L machine features a net sheet width of 5,600 mm, a maximum operating speed of 2,200 mpm, and a production capacity of over 80,000 tons/year. The machine is equipped with the fully hydraulic TT Headbox-MLT, TT NextPress of upgraded design, a third-generation TT SYD, gas fired TT Hood and Air System engineered with several steps of energy recovery.
The turnkey supply includes the complete stock preparation system, Toscotec’s patented TT SAF® (Short Approach Flow) with a double dilution system designed to ensure a reduction of electrical consumption. The electrification and controls, dust and mist removal systems, boiler plant, bridge cranes, air compressor station, roll handling and wrapping systems, and hall ventilation with conditioning system complete the production line. The scope also includes one OPTIMA 2600 slitter rewinder fitted with automatic shaft puller and dedicated dust removal system. Vajda Papír also purchased a comprehensive service package with detailed mill engineering, erection, commissioning, start-up assistance, and training.
Attila Vajda, owner and managing director of Vajda Papír, says, “We found in Toscotec the right partner to realize our expansion strategy according to plan. Based on their extensive experience with turnkey operations, our confidence in Toscotec’s ability to successfully complete complex tissue projects on a tight timeframe was a key factor in our decision. At Vajda Papír we select the most advanced and energy efficient technology to manufacture premium tissue quality for our customers and consumers.”
Marco Dalle Piagge, sales director of Toscotec, comments: “We are very happy to begin an important partnership with Vajda Papír. Toscotec strengthens its position as global leading supplier of turnkey solutions for the tissue industry. Delivering a complete tissue line on a turnkey basis according to schedule, and assuming responsibility for the achievement of performances for the entire supply requires significant expertise. We are the only tissue machinery manufacturer with nearly 20 years of experience in turnkey projects across 4 continents.”
Matteo Giorgio Marrano, Toscotec sales manager, says, “With Vajda Papír’s order, Toscotec increases its market penetration in Eastern Europe with three major tissue projects sold in the last two years, including two double-width machines. This new line will be equipped with advanced and energy-efficient technology, including Toscotec’s shoe press and TT SYD of latest generation, and high-recovery TT Hood.”
About Vajda Papír Kft.
Founded in 1999, Vajda Papír is headquartered in Budapest and operates 3 sites in Budapest, Székesfehérvár and Hungary’s biggest and most modern integrated tissue mill at Dunaföldvár, south of Budapest. It manufactures 110,000 tons/year of toilet tissue, handkerchiefs, towels, and napkins. Vajda Papír owns the famous brands Ooops, Sindy, Star and Lilla and distributes its products to the consumer and AfH markets in Eastern Europe.
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Toscotec has received an order from Sappi to supply a TT SYD Steel Yankee Dryer to their mill in Stanger, South Africa. The TT SYD was delivered in record time only 20 weeks after the order. The start-up is planned for the third quarter of 2021.
The cylinder was shipped off from Toscotec’s fully integrated and innovative TT SYD Technology Center in Massa (Italy), where Toscotec manufactures all its steel Yankees. The Center is conveniently located three kilometers away from seaport to expedite shipping operations of large diameter Yankees. The scope of supply includes the Yankee steam and condensate system and Toscotec’s patented head insulation designed to ensure maximum thermal energy efficiency. Toscotec will provide the complete project management, erection supervision, commissioning, and start-up assistance.
Nash Ayer, Procurement Manager at Sappi Southern Africa Ltd., comments, “We decided on Toscotec because they met our foremost selection criteria of high energy efficiency and reliability. The choice of leading-edge technology such as TT SYD that will increase the energy efficiency of our tissue line is part of our strong commitment to climate-smart solutions. Given the short timeframe we had on this project, Toscotec gave us their full support by shortening the delivery time.”
Fabio Bargiacchi, Toscotec’s Sales Manager, says, “We are glad to start a new cooperation with Sappi, one of the largest and most innovative pulp and paper producers worldwide. The 20 weeks delivery time obviously posed a big challenge but Toscotec achieved an outstanding result by tapping into the great manufacturing flexibility of its TT SYD Technology Center. With this order, Toscotec further strengthens its position in South Africa, where we have been awarded six new projects in the last 5 years.”
With over 200 TT SYD operating in 5 continents across the globe, Toscotec is the undisputed market leader of steel Yankee dryers holding more than 70% market share. Toscotec has manufactured the biggest steel Yankee dryer in the tissue sector, and its TT SYD has been selected for a wide range of applications, including tissue, MG paper, TAD, and tobacco.
Toscotec’s continuously growing experience of Yankee dryers operating under the most diverse conditions drives the progress of TT SYD’s design and services. In 2021, Toscotec launched TT Defender®, a breakthrough patented innovation that provides Yankees with an internal protection coating against corrosive steam.
Established in 1936, Sappi is a leading global provider of products made from woodfibre-based renewable resources, including raw materials (dissolving pulp (DP), wood pulp and biomaterials) and end-use products (tissue, packaging and specialty papers, graphic papers, casting and release papers, and forestry products). It operates 19 production facilities in Europe, North America, and Southern Africa, manufacturing 5.7 million tpy of paper, 2.4 million tpy of paper pulp, and 1.4 million tpy of dissolving pulp. Sappi’s global sales and distribution network reaches over 150 countries.
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GrandBay Group placed an order with Toscotec for one AHEAD 2.2L complete tissue line to be installed at its subsidiary Papelera Internacional in Rio Hondo Zacapa, Guatemala. The start-up is scheduled for late 2022.
The AHEAD 2.2L machine (PM7) has a sheet trim width of 5,500 mm, a design speed of 2,200 m/min, and an annual production capacity of over 60,000 tons. It features TT NextPress new generation shoe press, a third-generation design TT SYD with heads insulation patented system, and diesel oil-fired TT Hood-Duo system. The machine is designed to deliver the maximum possible drying efficiency with the lowest energy consumptions.
The supply includes the stock preparation system, fiber recovery system, and Toscotec’s patented TT SAF® (Short Approach Flow) equipped with a double dilution system to ensure low electrical consumptions. The scope also includes Toscotec’s proprietary DCS system, electrification, and controls, and an in-line shaft puller integrated in the pope reel section. Toscotec will provide a complete turnkey service package with detailed mill engineering, erection, commissioning, training, and start-up assistance.
Alberto Matos, Project Engineering Manager at GrandBay Group, says, “We had a very positive experience with Toscotec’s technology having had a TT SYD running for a few years now. We now have high expectations on the performance of their AHEAD tissue line, first and foremost in terms of energy efficiency. This project represents a milestone of our growth strategy: we trust that Toscotec’s expertise and state-of-the-art technology will enable us to achieve our targets.”
Gabriele Romanini, Toscotec’s Sales Manager, says, “We are pleased to partner with Papelera Internacional on this important project. This new AHEAD 2.2L line features Toscotec’s most advanced technology. In particular, the combination of the shoe press with the steel Yankee guarantees a significant reduction in energy consumption and an improvement in tissue quality.”
About Papelera Internacional S.A.
Papelera Internacional is part of the GrandBay Group, a leading Latin American company established in 1953, dedicated to the manufacturing, conversion and sales of personal care and home products of premium quality with presence in more than 25 countries in the Andean region, Central America and the Caribbean.
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Toscotec will supply a third-generation design TT SYD Steel Yankee Dryer to the South Korean tissue manufacturer Mirae Paper at their Jeonju paper mill. This is a repeat order from Mirae Paper who installed their first TT SYD on PM3 in 2013. The new steel Yankee will replace PM2’s existing cast-iron cylinder and it is scheduled for start-up in the second half of 2022.
The third-generation design of TT SYD Steel Yankee Dryer benefits from an ideal ratio of the weight, width and pitch of the internal ribs and the optimization of the shell thickness. The scope of supply includes the condensate removal system and Toscotec’s patented heads insulation for maximum thermal energy efficiency. The associated services include the complete project management, erection supervision, operation and maintenance training, commissioning and start-up assistance.
The TT SYD will be manufactured at Toscotec’s fully integrated TT SYD Technology Center in Massa (Italy), situated just 3 kilometers away from seaport to ensure fast and safe shipping operations.
Toscotec is continuously upgrading the design of TT SYD, benefiting from the vast experience of over 200 TT SYD running across 5 continents worldwide under the most diverse operational and environmental conditions. This year, Toscotec has launched TT Defender®, a breakthrough patented innovation that equips TT SYD with an internal protection coating against corrosive steam.
Yeong Rok Lee, Mirae Paper’s Production Manager, says, “The steel Yankee on PM3 has been operating efficiently for over 8 years, allowing us to reduce our thermal energy consumption by a significant amount. We expect the new Yankee on PM2 to be as reliable and to deliver even higher performances, considered the design upgrades that Toscotec has implemented on their TT SYD since our first installation. We consider the Yankee dryer to be the core component of our tissue machine’s drying capacity. We chose the best technology available in the market, with all the technical support we need from an expert supplier.”
Gabriele Martinelli, Toscotec’s Sales Manager, says, “It is very rewarding that Mirae Paper has chosen Toscotec for the second time on their Yankee replacement. Toscotec strengthens its position in South Korea, where it is the only supplier of steel Yankee dryers, with 12 TT SYD sold in 9 years, including two installed on Toscotec’s AHEAD tissue lines.”
This order was obtained with the support of CleanTech Corporation, Yongin, South Korea.
About Mirae Paper Co., Ltd.
Established in 2000, Mirae Paper operates one paper mill in Jeonju, South Korea. The company manufactures approximately 65,000 tpy of high quality tissue, including toilet tissue, handkerchiefs, and towels, using recycled fibers. It distributes its products mainly to the Korean market.
Toscotec has launched the new generation design of its shoe press TT NextPress, featuring superior drying performances and energy savings, resulting from R&D activities in cooperation with Voith. TT NextPress delivers a stable after-press dryness rate of more than 47% on a tissue line operating above 2,000 mpm speed. This dryness level ensures a substantial reduction of energy consumption, as the Yankee and the hoods use significantly less thermal energy to complete the paper drying process.
Superior Dewatering delivers higher Dryness
A new shoe shape has been introduced to enhance the nip width and increase the peak pressure at the nip outlet, reshaping the outward pressure into a steeper curve. This eliminates the risk of paper re-wetting at the exit of the nip, and increases sheet dryness, without affecting the belt’s life.
Continuous Nip Control for maximum Reliability
Machine operators can now visualize on the DCS (Distributed Control System) the actual nip pressure of TT NextPress in real time. The operator can regulate the nip pressure at which the TT NextPress is loaded onto the Yankee resulting from both a theoretical and empirical system, as the nip pressure is calculated based on the shoe press loading system and also measured by the load cells installed on the press mechanical stop.
Higher Precision: the perfect fit for Rebuilds
In rebuilds, the installation of a shoe press on an old-style cast iron Yankee can compromise the lifetime of both the felt and the belt. Toscotec has designed a dedicated solution on the TT NextPress consisting of multiple independent pressure zones, up to 14 in total, of which 12 are located on the edges. This design ensures a perfect fit between the shoe and the Yankee deformation, and maximizes the clothing lifetime.
Improved Safety and Yankee Protection
TT NextPress nip pressure lines are fitted with a pressure accumulator pre-charged with nitrogen, which is installed inside the belt as close as possible to the loading pistons. The accumulators absorb instantaneous overloads or pressure increases on the line due to the presence of external elements or paper wads in the nip area. This eliminates the risk of any possible damage to the Yankee dryer.
The new TT NextPress builds on the features of its previous version which have been widely appreciated by tissue producers around the globe. These include:
- the hydraulic loading system, which ensures top pressure uniformity and reliability
- the extreme flexibility offered by the shoe tilting regulation during operations
- the maximization of the belt lifetime both through the continuous digital monitoring of the heads position with regular lateral movements of the belt, and through the sleeve tensioning device actuated by hydraulic cylinders, which delivers a constant and adjustable stretching force.
Toscotec, together with Voith, has sold more than 60 shoe presses for tissue machines all over the world.
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Toscotec boosts the drying efficiency of its tissue lines with TT Drying Equilibrium, a simple and reliable system that ensures an optimal and automatic regulation of the air balance in the Yankee hoods and air system. The system was originally designed by Voith and transferred to Toscotec for further development in the synergy-creating cooperation established with the acquisition. TT Drying Equilibrium measures several attributes of the air going in and out of the hoods, and automatically adjusts the system to guarantee the highest productivity and energy efficiency.
Stefano Pecchia, Energy Technology Director at Toscotec, says: “In a properly balanced hood system, the masses of gases - vapour and dry air - that are fed into the system are equal to those that go out through the chimney as exhaust air. This balance is crucial to avoid fresh air getting in and hot air going out during manufacturing; in this way, you can achieve maximum drying efficiency. We recommend the automatic balancing system especially on tissue machines that frequently change basis weight during the production cycle. It would be more complicated for operators to balance the system manually at every change; TT Drying Equilibrium makes these adjustments automatically, in a much faster and more effective way.”
The control and regulation logics are managed by a dedicated PLC (Programmable Logic Controller) that communicates with the DCS (Distributed Control System) of the tissue machine. The mill can easily access the data collected, stored and organized by the PLC on local monitors, tablets, or smartphones, through a remote connection.
Ensure product quality
A lack of balance in the hoods can be triggered both by over-pressure that causes hot air to go out, and by under-pressure that causes cold air to be pulled into system through the gap between the Yankee and the hoods. These imbalances will reduce energy efficiency, give rise to paper quality issues, cause environment-related issues, and potentially be unsafe to personnel. In fact, in the event of air suction, cold air on the paper can lead to its detachment from the Yankee surface and to an uneven moisture profile. In case of over-pressure, hot air can cause overheating of the surrounding area with increased fire risks, discomfort or danger for operators, possible damage to adjacent equipment, and deterioration of the environmental conditions of the machine hall. By ensuring hood balance, TT Drying Equilibrium contributes to effectively avoid these issues and deliver the best possible product quality.
An effective twofold Balance Control
TT Drying Equilibrium consists of a set of various transmitters of physical data, including speed, flow rate, temperature, humidity, and pressure, and of a data acquisition and processing system.
The calculation algorithms produce the mass flow rates inside all the air ducts leading into and out of the Yankee hoods, including outgoing air, make-up air, and combustive air both on wet-end and dry-end.
The combustion air is regulated by the burner control system, while the flow of exhaust air can be regulated by the moisture control loop. TT Drying Equilibrium controls the dampers that allow for make-up air to enter the system, thereby maintaining a condition of balance over time.
In addition to controlling the air mass flows, the system also checks the actual balance using temperature sensors installed just outside the Yankee-Hoods gap and of pressure transmitters inside the hoods. As a result, TT Drying Equilibrium delivers an effective twofold balance control in real time, based on the calculated balance of the masses, and on the confirmation that hot air is not escaping or cool air is not being pulled in around Yankee and Hoods.
A key tool to monitor Machine Efficiency & optimize Production and Maintenance
TT Drying Equilibrium also enables real time monitoring of the energy performance of the tissue machine. It processes production data acquired from the DCS and produces precise figures or trends relating to the tissue machine’s energy consumptions, including steam, gas, and electrical power consumption.
It also acquires key data of the air system’s heat recovery units, including inlet and outlet temperatures and flow rates, to monitor their performance, and plan maintenance activities. This allows the mill to check production efficiency by product over time, and to perform preventive maintenance.
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Dunn Paper selected Toscotec for the rebuild of the wet section of PM2 at its Menominee paper mill in Michigan, USA. The paper machine produces specialty papers including MG grades and flexible packaging products.
In 2017, Toscotec had installed a custom-made TT Headbox at Dunn Paper’s St. Catharines paper mill in Canada. Based on the successful experience of this rebuild, Dunn Paper Menominee asked Toscotec to create a preliminary engineering solution that met PM2’s production and quality targets. Finally, Dunn Paper awarded the rebuild order to Toscotec, valuing the importance of a fully-customized technical offer based on the analysis of the machine’s operating data. Toscotec will supply the approach flow system, and a hydraulic TT Headbox-SL fitted with dilution control. The service package includes erection supervision, commissioning, and start-up assistance.
Steve Michalko, Dunn Paper Manufacturing Director, says: “In recent years Dunn Paper has been making significant investments into our mills and processes in order to better ourselves and meet the demands of the ever changing market and standards of our growing customer base. By upgrading to a Toscotec dilution profiled headbox in addition to their screening and water system improvements, we will improve the uniformity and formation of our base sheet, increasing our capability to meet current and future customer requirements. A big thanks to Toscotec for helping with this mill improvement.”
Fabrizio Charrier, Toscotec Sales Manager, says, “Having the chance to support Dunn Paper Menominee on this rebuild makes me very proud. Toscotec’s TT Headbox-SL has a consolidated design that has proved successful on numerous references over the years. This important project confirms that Toscotec can rebuild all sections of the paper machine, and this will open up new opportunities for Toscotec in North America to supply key paper machine components, project studies and tailor-made solutions.”
About Dunn Paper
Established in 1924, Dunn Paper is a tissue and specialty paper manufacturer and converter. It operates 7 paper mills throughout the USA and Canada. With a focus on product development and sustainability, Dunn Paper caters to top brands and converters across North America, creating innovative sustainable paper products for food services, the medical and retail industries, as well as hygiene products.
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In 2020, Sofidel added 120,000 tons a year to its production capacity in the USA with two Toscotec AHEAD 2.0L paper machines in 5,500 millimetre format with an operating speed of 2,000 metres a minute. Toscotec has delivered a turnkey product for the tissue-making area of Sofidel America’s integrated paper mill in Inola, Oklahoma. Since the launch of two new lines, Sofidel has been manufacturing premium quality tissue paper, in compliance with its rigorous quality standards, and has maintained a high level of operating efficiency, fully benefiting from the energy and environmental efficiency of Toscotec’s AHEAD lines, which feature the TT SYD Steel Yankee Dryer and high energy recovery TT Hoods. In this interview, Simone Capuano, the Executive VP, Operations & Supply Chain, of Sofidel America Corp. discloses the strategy underpinning this investment and tells us what Sofidel has achieved so far at its Inola production base.
Sofidel America’s new integrated production base in Inola: what were the reasons for this expansion and for choosing Toscotec’s technology?
The construction of an integrated plant in Inola (Oklahoma) is an important part of the growth strategy that Sofidel has implemented in the USA since its arrival in the country in 2012. After Circleville (Ohio), this is the second greenfield investment of our Group in the USA, aimed at increasing our production capacity and our geographical coverage, which means having plants close to our customers - in this case, specifically, we are in the southern region - in order to improve our service and contain logistical costs. In this context, Toscotec was the right choice, because its technology is efficient both from the energy and environmental points of view, and because of the experience and flexibility they have gained in our sector.
Toscotec was your turnkey supplier for paper mill production on the Inola project. Was it helpful for you to have a single company as your reference point for this part of the supply?
Building a new paper mill from scratch is never an easy task, both for technical and organizational reasons. In Oklahoma, like everywhere else in the USA, we have been able to count on excellent collaboration from local institutions and partners. We certainly found it very helpful to have a single supplier as our contact for the paper mill production part, especially since part of the project was carried out in the first and most complicated stage of the COVID-19 emergency, with all the problems that implied.
Are you satisfied with Toscotec’s management at this time of global emergency?
Even though we had to face unpredictable and complicated situations, Toscotec's flexibility, contribution and spirit of collaboration have never been lacking. We appreciated their dedication and problem-solving skills.
Once Toscotec’s machines came on line, did you see an increase in the OEE (Overall Equipment Effectiveness) compared to processing reels from other production sites, as you were doing before? Has converting efficiency improved? If yes, why?
Having an integrated plant has already improved production efficiency. Furthermore, the AHEAD 2.0L machines used on our lines represent a tried and tested technology that did not require any fine-tuning. As we expected, they were immediately found to be in line with the needs of our customers. The fact that we could count on reels with a larger diameter and constant quality has definitely allowed us to increase the efficiency of our converting lines.
What grades are you currently manufacturing on PM1 and PM2? What is your assessment of product quality?
The quality standard is high and meets our customers’ requirements and, at the same time, it allows us to achieve excellent performances at the plant in terms of energy efficiency and optimization of raw material use. This is in line with Sofidel's commitment to reconcile the market and consumption needs with those of sustainability. On the two machines, we are producing various grades both for toilet tissues, with particular attention to Super Soft papers, and kitchen towels.
Are you satisfied with the specific consumption of chemical products per ton of paper produced that is being recorded by the two machines?
Yes, we are also recording significant improvements in this area, although the optimizing of the entire system must continue.
Overall, how would you describe the cooperation with Toscotec?
A positive cooperation built on hard work and mutual commitment to continuous improvement.
The new AHEAD 1.5S machine has a trim width of 2,850 mm, an operating speed of 1,850 m/min, and produces more than 30,000 tpy of premium quality tissue. The machine configuration is designed to guarantee top energy efficiency with TT NextPress shoe press design, TT SYD Steel Yankee Dryer, and steam-heated TT Hood-Hybrid.
The supply included the stock preparation equipment and accessories, the patented TT SAF (Short Approach Flow) system, the fiber recovery system, dust and mist removal systems, and a complete slitter rewinder line, with dedicated dust removal system. Toscotec also provided a comprehensive service package, including the tissue machine’s erection, erection supervision, commissioning, training and start-up assistance, as well as YES-CONNECT-VISION augmented reality solution for remote service.
Torpong Thongcharoen, Managing Director of C.A.S. Paper Mill, said: “With this new line C.A.S. Group enters the tissue market. We are already producing high quality tissue, and we expect to kick off distribution very quickly. Throughout the entire project, including the hardest times during the pandemic, we always had a very good cooperation with Toscotec, who proved to be the experienced and skilled supplier we expected, managing the project with great flexibility and supporting us all the way to our target.”
Marco Dalle Piagge, Toscotec Sales Director, comments: “This start-up is a reward to us all for the hard work we put into this project in order to successfully complete it during Covid-19. This AHEAD line is designed to deliver top energy efficiency that results in low energy consumptions and low operating costs. C.A.S. Paper Mill is now fully equipped to enter the tissue market from an advantage position.”
About C.A.S. Paper Mill Co., Ltd.
C.A.S. Paper Mill Co., Ltd is part of the Charoen Aksorn Holding Group (C.A.S. Group). Established in 1963, C.A.S. group is a well-established paper trading company in Thailand. In 2013, the Group acquired from Norske Skog (Thailand) a newsprint mill in operations since 1994, and it was named C.A.S. Paper Mill. The company operates a pulp and paper mill situated in Sing Buri, near Bangkok, Thailand.
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