Displaying items by tag: Toscotec
After a complete dryer section rebuild supplied by Toscotec, Cartiera di Ferrara fired up PM1 at its mill in Ferrara, Italy. Toscotec modified the entire dryer section, without changing its overall length and therefore leaving the positions of the press and the pope reel unchanged. This allowed for a very short shutdowntime because civil works were not necessary to achieve the planned production increase. The paper machine achieved stable production immediately after start-up.
Toscotec refurbished the first dryer section with the supply of new felt rolls, guide and stretchers, and a modification of the frame structure. The second section was completely rebuilt with 16 new TT SteelDryers of 1,829 mm diameter designed for an operating steam pressure of 10 barg. Toscotec supplied new silent drives for the transmission of the entire dryer section that significantly improved PM1’s conditions for operation and maintenance. The scope comprised a full set of services, including mechanical erection, supervision, commissioning, and start-up assistance.
Alessandro Castelletti, Mill Manager of Cartiera di Ferrara, says: “Toscotec executed the rebuild with competence and according to the agreed time plan. We boosted PM1’s operating speed because of the increased drying capacity of our new dryer section. We will progressively continue to raise the speed as we still have margin. The production is stable, and we are happy with the results we achieved so far.”
Stefano Baldi, Toscotec Project Manager, says: “We lived up to the double challenge of a tight project schedule that began right before Italy enforced nationwide Covid-19 restrictions. We managed to complete on time the pre-assembly phases during lockdown, and then finalized the installation according to schedule. We are happy to see that Cartiera di Ferrara is already increasing their production capacity as a result of this rebuild.”
About Cartiera di Ferrara S.p.A.
Established in the 1940s, Cartiera di Ferrara is an integrated paper mill producing high quality core board and high-resistance tubes and cores. It operates one paper machine at its production base in Ferrara (Italy). Its products are sold to the Italian and export markets.
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Cartiera San Giorgio successfully started up its PM1 after the complete rebuilt of its dryer section by Toscotec. PM1 has a trim width of 2,500 mm, and produces wet creped tissue in the basis weight range from 30 to 50 gsm, using virgin cellulose and recycled paper.
Following the installation of a TT SYD Steel Yankee Dryer that replaced PM1’s existing cast-iron Yankee in 2012, Toscotec has now completed the full upgrade of the drying section of this paper machine by rebuilding the post-dryer section. The rebuild supply included eight TT SteelDryers designed for an operating steam pressure of 10 barg, and the tail threading system installed between the TT SYD and the post-dryer section. The project also includes the engineering design, on site erection, commissioning and start-up assistance.
Alessandro Ardinghi, owner of Cartiera San Giorgio, comments: “The targets of this rebuild have been fully accomplished. We optimized PM1’s production and significantly improved the moisture profile on the edges. We have known Toscotec for many years, and we are happy with how they managed the project and delivered on the results we expected.”
Gian Luca Fornesi, Head of Sales Application at Toscotec, says, “With this project, Toscotec confirmed its ability to address and resolve specific production problems. For Cartiera San Giorgio, we carried out a survey and developed a custom-made design for their TT SteelDryers, in order to meet their needs and eliminate their production bottlenecks.”
About Cartiera San Giorgio
Founded in 1974, Cartiera San Giorgio manufactures wet creped tissue jumbo rolls and tissue products for the AfH market. The current production capacity is 21,000 tpy. Its product range for the AfH and private label markets includes towels dispensers and tissue products used in working environments.
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Toscotec has recently introduced TT Defender, a leading-edge patented innovation that provides Yankee dryers with an effective internal protection coating against corrosive steam. Toscotec has successfully tested TT Defender at Lucart Group’s Diecimo tissue mill in Italy on a TT SYD that came online in February 2020.
Danilo Calamari, Lucart’s Paper Mill Senior Engineer & Cogeneration Plants Manager, is the technical expert who closely followed the project in Lucart. In this interview, he shares Lucart’s experience with TT Defender and his professional views on the results they achieved so far.
The TT SYD installed on your PM5 in Diecimo is fitted with TT Defender. During the regular checks you performed 6 months after start-up, you personally entered inside the Yankee. Which conditions did you find?
D.C.: I was pleasantly surprised at how good the Yankee looked inside. During our regular Yankee checks, we often find some magnetite deposits and soda straw blockage. Instead, the TT SYD on PM5 appeared as if it were new, or even better: the entire internal surface and all the straw pipes were perfectly clean. Evidently, during its six months of operation, no magnetite deposits had formed inside the Yankee. This result validated our decision to participate in this project. To be honest, at the beginning when Toscotec suggested they test this new technology on our TT SYD, we were not entirely convinced. Finally, we decided to get on board, because we have had a very good cooperation with them for many years, and we trust their professionalism and reliability as a supplier.
Mill technicians know very well that in the ordinary operation of the steam and condensate system, it is quite common to go through transitory phases or issues that cause some of the chemical and physical values under control to fall short of the requirements for the proper functioning of the plant. Does TT Defender represent an additional security in this regard? Do you think that it allows your Yankee to have a greater tolerance to these kind of normal variations?
D.C.: Yes, we do. TT Defender allows us to overcome some possibly critical issues in the chemical treatment of the steam and condensate system of PM5 without consequences. We can now successfully manage these phases that are completely normal throughout the year.
Before the TT SYD with TT Defender, Toscotec had installed another TT SYD on your PM6, which is right next to PM5 and shares the same steam and condensate system. In terms of drying performances, did you find that the drying capacity of the steel Yankee with TT Defender was any different from the other?
D.C.: Apart from TT Defender, the two TT SYDs installed on PM5 and PM6 have the same characteristics, so we could easily compare their performances under various operating conditions. We did not find any limitation in the drying capacity of the TT SYD with TT Defender. Before the application, one might wonder if TT Defender could hinder the heat exchange between the Yankee’s internal and external surface on which its drying capacity is based upon. The actual result is that TT Defender does not affect the Yankee’s thermal efficiency in any way. In one year of operations, we found that the two TT SYDs on PM5 and PM6 perform equally well.
Do you think that TT Defender allows you to eliminate the risk of longer maintenance stops due to the obstruction of soda straws?
D.C.: At Lucart, we perform one regular internal Yankee inspection per year. We will check PM5’s TT SYD this summer, but what we can say now is that we are not experiencing any issues with tissue quality that could point to soda straw blockage. The paper we are producing on PM5 is high quality and has a very uniform cross-direction moisture profile. This suggests that when we will open up the Yankee later this year, we will most likely do just a quick check, without allocating extra personnel and extend the downtime in order to clean or replace soda straws. With TT Defender, we expect to find a Yankee that is always clean, and allows us to realize the best production efficiency in terms of both quality and quantity.
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Toscotec upgraded its YES-CONNECT-VISION AR (Augmented Reality) system to provide faster and more effectiveremote services. After launching the first version in 2018, Toscotec perfected the system based on user feedback and practice in the field. With this improved tool, mill operators wearing an ergonomic helmet fitted with a high definition camera send out high-resolution images and audio in real time, becoming the eyes and the ears of Toscotec’s service team inside the mill.
Toscotec’s experts can actively interact with these inputs in real time by highlighting components in the operator’s field of view, sending relevant documentation to their helmet’s visor and guiding them on adjusting the machine. Toscotec’s service team can acquire all the information they need to provide solutions, get around lack of technical know-how, or language-related issues in communication.
YES-CONNECT-VISION is designed to ensure maximum safety to the operator who is wearing the helmet with dust-tight and watertight hardware. With an easily adjustable binocular visor, a wide angle camera that offers a 150-degree visual field, a selective microphone and noise-cancelling headset, technicians can safely move around in the mill with large visibility of surroundings, and operate hands-free, while receiving clear audio signals even in highly noisy areas.
YES-CONNECT-VISION digital solution increases service efficiency, thereby reducing downtime and boosting production efficiency. When travel options are limited or if it’s desired to retain the option of on-demand remote service, Toscotec offers an effective tool that reduces downtime, costs and carbon emissions.
Girolamo Panepinto, Toscotec Start-up & Service Software Engineer, says: “YES-CONNECT-VISION is perfectly suited for trouble-shooting service, on-remote factory acceptance tests, and commissioning tests. Customers can also use it for one on one training at the customer site, or group training from the Toscotec factory floor. For instance, a Toscotec engineer could demonstrate a maintenance task with up to 11 remote connected viewers. With price-competitive service subscriptions, paper mills can get 24/7, worry-free service. We are simply a phone call away from the solution to their technical problem.”
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Toscotec successfully accomplished an extensive rebuild of Russian containerboard manufacturer JSC Yarpaper’s PM1 at their mill in Yaroslavl, near Moscow. PM1 has a wire width of 2,830 mm and produces 100% recycled-based fluting and test liner in the range from 90 to 175 gsm.
The rebuild has optimized the entire paper machine, from the approach flow system to the dryer section, and has achieved the targets of production increase and quality upgrade.
The scope of the rebuild included the approach flow system, with screens, fan pumps, a TT Headbox-H equipped with TT D-Profiler dilution control system, a newly designed Fourdrinier make up, and the optimization of the sheet path in the press section.
Toscotec installed a completely new dryer section, fitted with 35 TT SteelDryers designed for 10 barg operating pressure, structural frame, canvas rolls, doctors, stabilization boxes, stretchers, guiding, tail threading system, oil lubrication unit, as well as mechanical drives for the entire line.
The project also included a complete service package with engineering, erection supervision, commissioning, start-up assistance, and training.
Igor Noskov, Project Manager of JSC Yarpaper, says, “We successfully completed a major rebuilding operation on our paper machine in difficult times during Covid-19. We have expanded our range of high quality containerboard papers to 90-175 gsm and have increased our reel width to 2,500 mm. This will allow us to better serve our Russian customers, and expand to Europe and the Middle East.”
Luca Nesi, Toscotec Start-up Engineer, comments, “The cooperation with Yarpaper was very good throughout the entire project. They provided the best conditions for Toscotec to work on site during the pandemic. We could thoroughly prepare the machine, so that at start-up we got paper on the pope reel shortly after sending stock to the new TT Headbox. It is a great satisfaction to witness the successful completion of such an extensive rebuild, where we newly designed or extensively rebuilt most sections of the paper machine to deliver a significant production increase.”
About JSC Yarpaper
Established in 2003, JSC Yarpaper specializes in the production of paper and cardboard, using 100% recycled raw materials that are certified according to FSC requirements. In 2020, it recycled 65,000 tons of waste paper. It currently produces 70,000 t/y of fluting and test liner. Its customer base is made of leading Russian corrugated packaging producers, including GOTEK, ARCHBUM, Stora Enso Packaging, Mondi Group, Yaroslavsky Karton.
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Europap Tezol Kağit will boost capacity with a Toscotec-supplied AHEAD 2.2S tissue machine at its integrated production base in Mersin, Turkey. This is a repeat order for Toscotec who already supplied a TT SYD steel Yankee dryer installed on their PM1 in 2012. The new line is scheduled for start-up in mid-2022.
The AHEAD 2.2S machine has a sheet trim width of 2,920 mm, a maximum operating speed of 2,100 mpm, and an annual production capacity of over 40,000 tons. It is equipped with TT NextPress with upgraded design, third-generation TT SYD, TT Reel-BulkyReel for optimal preservation of bulk and softness, and high efficiency TT Hood with automatic balancing system.
The supply features the complete stock preparation system and Toscotec’s patented TT SAF® (Short Approach Flow) equipped with a double dilution system to ensure electrical consumption reduction. The scope also includes Toscotec’s proprietary DCS system, electrification and controls, as well as dust and mist removal systems. Two OPTIMA slitter rewinders fitted with an automatic shaft puller complete the supply. Toscotec will provide a complete service package with detailed mill engineering, erection supervision, commissioning, training, and start-up assistance.
Ersin Tezol, CEO of Europap Tezol Kağit, says, “Our production capacity expansion required the most advanced technology at a cost-attractive price. Toscotec’s technology was the best choice to meet the strict environmental requirements of our company and the high quality standards of our super-prime brands, especially for softness and hand feel.”
Matteo Giorgio Marrano, Toscotec’s sales manager, says, “This AHEAD 2.2S machine will allow Europap Tezol to achieve its target of production increase and prime quality. The configuration with TT NextPress and TT SYD of new generation and high recovery TT Hood aims to provide the highest possible level of energy efficiency on a tissue production line. Toscotec also strengthens its presence in the Turkish market, which is growing into a key market in the EMEA region.”
About Europap Tezol Kağit San. Tic. Inc.
Established in 2004, Europap Tezol is a major manufacturer in the Turkish tissue market and it operates two tissue mills with integrated converting, in Torbali-Izmir and in Mersin-Tarsus (Turkey), with an annual production of 100,000 tons. Tezol distributes its branded products and AfH tissue, including wipes, napkin, toilet and towels, in Turkey, as well as Europe, the Middle East, Russia and Latin America.
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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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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.
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.
In June 2020, Toscotec successfully rebuilt the approach flow and wet end of PM4 at Papeterie Le Bourray in Saint-Mars-la-Brière, France. After two months of stable production, PM4 exceeded the performance targets relating to the improvement of sheet formation quality and cross direction basis weight profile. After the rebuild, the operating speed of PM4 increased by up to 10%.
The project included a new fan pump and a fully hydraulic TT Headbox. Toscotec also supplied a complete service package, comprising detailed engineering, dismantling operations, erection, commissioning, start-up supervision, and training.
Through the joint effort of Toscotec and Papeterie Le Bourray, the project pushed ahead during the Covid-19 lockdown in France and Italy, and it was executed according to schedule.
Alexandre Pappalardo, Head of Maintenance & TN at Papeterie Le Bourray, says, “We are very satisfied with the outcome of the project. Toscotec respected the time limits of machine shutdown and the new TT Headbox delivered on the performance targets. The restrictions in place during lockdown required extra efforts from both companies, but our good cooperation made it possible to complete the rebuild on schedule.”
Andrea Paganucci, Project Manager at Toscotec, says, “Papeterie Le Bourray provided Toscotec Service team with the best possible working conditions during lockdown. We were united by a common determination to achieve the project targets and we succeeded. The new TT Headbox features a tailor-made design that allows the mill to operate in the current Tisco Former configuration but also in Crescent Former configuration in the future.”