Displaying items by tag: acelli paper

Friday, 04 September 2020 12:55


With this operation, A.Celli Paper acquires the intellectual property of the historic Piedmontese company, becoming the main player in the sector, lead by a 100% Italian ownership.

A.CELLI PAPER SPA, main affiliate of ITALIA TECHNOLOGY ALLIANCE group, announces the acquisition of PMT ITALIA - PAPER MACHINERY TECHNOLOGY, a company operating in the production of machinery for tissue and paper industry.

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PMT ITALIA, based in Pinerolo, was born in 2000 but shares a long tradition of expertise and success as former subsidiary of Beloit Corporation. It was in fact, for over 50 years, the main European headquarters of the American group with the name of Beloit Italia. Thanks to its consolidated know-how and skills, PMT ITALIA has successfully operated in the tissue and paper market for a further twenty years.

With the entry of A.CELLI PAPER SPA, PMT ITALIA’s range of products will get fresh impetus through synergies with the organization and know-how of A.CELLI PAPER SPA. The specific and cutting edge technologies developed in the field of packaging papers, cardboard, printing, will be available for the group worldwide customers, and the Customer Service division will be restructured and strengthened as well, in order to guarantee continuity and reliability to customers operating with ex-Beloit / PMT ITALIA machineries.

«With this operation, carried out in a period of general uncertainty, we want to demonstrate the desire to guarantee cutting-edge technologies and timely assistance for Italian and foreign companies operating in the strategic sector of paper and tissue.» states Mauro Celli, shareholder of ITALIA TECHNOLOGY ALLIANCE «Maintaining this heritage in Italy is an important step that will bring benefit to the entire paper supply chain, including the district of Lucca.»

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The over ten-year collaboration between the two companies continues after the three A.Celli rewinders purchased for the Xiaogan plant at the beginning of the year.

The Asian Pulp and Paper (APP) Group, one of the largest and most important companies in the world as regards the production of paper, tissue and packaging materials, has signed the purchase contract for three A.Celli E-WIND® tissue rewinders T200S shaftless for the Gold Hongye Paper production plant located in Nantong, in the Chinese province of Jiangsu.

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The supply will be used to process mother rolls with diameter of 3000 mm and a paper width of 5.6 m, with basis weights varying from 10.5 to 45 gsm, and with a maximum operating speed of 1100 mpm. Particularly noteworthy is that two of the rewinders are equipped with unwinders with the addition of the calender as an optional.

After the purchase of three E-WIND® T-200S for the Chinese factory located in Xiaogan and the order for the tissue rewinders supplied in 2017 to APP Indonesia, this last agreement definitively confirms the customer's trust and satisfaction with the solutions and services provided by A.Celli Paper and A.Celli Shanghai.

Published in Asian News
Tuesday, 28 July 2020 06:48

4 examples of goods storage automation

acelli products r way agv

The fourth industrial revolution, known as Industry 4.0, is now well underway, and the new frontier is automation, or the use of digital technologies to manage productivity.

The way that industries evolve into "intelligent" factories by upgrading their production methods and logistics is not only a matter of technological change, but also involves cultural adjustment. This process need not be sudden and drastic; indeed, it requires time and planning to attune the various structures and processes to the habits and dynamics of your team.

A smart factory cannot be created overnight, simply by purchasing advanced digital systems. It needs to be a gradual process that sustains tradition while leading a business into the digital age.

Here are some examples of companies that relied on TecnoFerrari & A.Celli synergy to automate their processes, and were able to resolve their problems and increase productivity without losing their character or abandoning their traditions.

1. Goods storage automation in Texhong Textile Group Ltd

Texhong Textile Group Ltd. is a Chinese company, specialising in the production and distribution of high quality yarns and fabrics. It is currently one of the leading suppliers in the global textile industry. This important group has decided to use A.Celli technology for the installation of a fully automated system for both warehouse management and the preparation of rolls for shipping. The system will be installed at the company's plant in Vietnam.

The order for the automated warehouse followed on from a previous order by the same customer for two  rewinders and two automatic packaging/roll handling systems. With this important order, A.Celli has now become responsible for the entire downstream section of the production line: from wrapping-packaging and storage in the warehouse (including all data tracking) to preparation of the rolls for loading. The system is a customised solution that involves the use of AGVs both for handling master rolls and empty shafts in the production area and for the process of managing the rolls: from picking them after packaging to storing them in the warehouse, and subsequently preparing the load for shipment.

A.Celli has once again proved to be an important player in the Asian market, capable of developing solutions that meet the disparate needs of customers, and responding with flexibility and promptness to the many variables involved in production and logistics.

2. Goods storage automation in Cartesar

The subject of recycling has become a prominent issue in recent years, and Cartesar is an expert in this matter.

The company was founded in 1974, and is based in Salerno on the Amalfi Coast. Right from the start, the focus has been on finding the best and most innovative solutions for producing recycled paper for corrugators, using solely waste paper as raw material.

After 40 years of successful business and uninterrupted growth, it became vital to automate the services of the production chain. This was achieved by using counterbalanced TGVCs with on-board roller conveyors for transporting rolls in a vertical position, whether inside or outside the factory. In this way, the rolls can be moved to the interchange bay of the warehouse, where other TGVC vehicles, fitted with grippers, then store the rolls on high shelves in multi-tier, multi-depth ground storage warehouses.

Thanks to the automation of the handling and storage systems, there have been significant reductions in the time required for such operations, resulting in a real increase in productivity. There are also savings in relation to having to pay workers to do low-skilled jobs, and these people can be re-trained to do higher-skilled tasks.

3. Goods storage automation in Commercarta

Tradition, quality, reliability, precision and technology are the distinguishing features of the Milanese company Commercarta, which has specialised in the packaging and graphic applications sector for over thirty years.

With the launch of the 4.0 protocol, the company found itself confronting yet another technological evolution, but decided to embrace it with open arms. The challenge was to ensure maximum safety for the personnel, while also reducing the possibility of error and improving the quality of the finished product.

The new initiatives have made it possible to execute in total safety all the operations involved in handling the rolls, from storage to production. They include manoeuvring the rolls with the tilter, and moving them along the connecting routes between the production facility and warehouse sheds, using fork-type TGVP vehicles with magnetic guidance systems. The automated handling equipment is fitted with all the most advanced safety devices, to protect both employees and goods. This helps to reduce the number of accidents at work and increases the quality of the products themselves, while also cutting wastage.

4. Goods storage automation in Fater

Where is the margin for improvement when a company is already the market leader in the production of absorbent personal products and bleaches?

In the new world of Industry and Logistics 4.0, it is becoming increasingly vital to automate warehouse logistics, enabling the company to respond quickly to customers' needs while also preserving the efficiency of mass production.

The Italian company Fater is well aware of this need and has proved to be a trailblazer. The business was founded in 1958, but since 1992 has operated as a joint venture between Procter & Gamble and the Angelini Group. Every year, this Pescara-based company invests about 4% of its annual turnover in innovation, constantly raising the bar in terms of results.

A few years ago, Fater decided to focus on innovating its processes, and invested part of its revenue in automating its production lines. By designing a magnetic guidance system and using TGVP vehicles with rotating forks for handling reels and pallets, it was possible to automate the entire process of servicing the production lines. This equipment could handle any sort of material: cellulose reels, scraps or packages on pallets, and could also pick and place it in multi-depth ground storage warehouses.

This type of automation has allowed Fater to achieve greater productivity, using machines that can operate for longer hours and without breaks at night. The company can now ensure even better quality in its products, with systems that guarantee total hygiene and reduce waste due to spillage. The data collected and transmitted during the various phases can be used for analysing just in time production methods, and the company's reputation for being at the forefront of technology is a considerable boost to its image.

Do you want to know more about the solutions adopted by these 4 big companies? Download the eBook "A.Celli R-WAY AGV and other tools to automate the warehouse" and discover all the advantages for your business!

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One of the most critical parts of the paper and tissue production line is the slitter rewinder, a machine that has traditionally required direct operator contact in order to manually set the knives and operate the core handling system.

However, companies often use obsolete systems that are unable to maximize production and are not equipped with adequate safety features. One company that discovered the benefits of the said upgrade was Kimberly-Clark Professional Malaysia. Thanks to this, they achieved a significant reduction in downtime, as well as greater safety and productivity. Here is their story.

Kimberly-Clark Professional Malaysia’s paper slitter rewinder upgrade

Kimberly-Clark Professional Malaysia is a leading producer of leading-edge hygiene and cleaning solutions for the workplace and washrooms, such as facial and toilet tissue, paper towel, napkins, wipes, skincare and sanitizers, under brands like Kleenex® and Scott®.

One area of the plant that Kimberly-Clark specifically wanted to work on was the slitting section of their slitter rewinder. The company wanted to achieve certain results; among these, the most critical ones were:

  • The improvement of cut precision and knife quality 
  • The reduction of maintenance time of the slitting section
  • The reduction of the cycle time of the core handling system
  • The improvement of the slitting section operators’ safety and the reduction of the hazards around the shaft puller 

Case study slitter rewinder upgrade KCC

After setting these goals, Kimberly-Clark contacted A.Celli to inquire about a new slitting system, and we were more than happy to provide a technical consultation to further understand their specific needs.

The project and the final results

After the aforementioned assessment, A.Celli’s proposal was to perform a technological upgrade consisting of the most up-to-date knife holders with top of the line material blades and a faster and easier blocking system.

Another significant part of the supply was the new semi-automatic cantilever shaft-puller, which replaced their old manual steel rope shaft-puller. Our solution operates by extracting the expandable reel spool from the jumbo roll and placing it into the core located on the V platform. This is done by a single operator, who uses the mill air pressure hose to manually inflate/deflate the expandable reel spool, eliminating the need to touch the roll or the reel spool.

Once the new paper slitting system was up and running, Kimberly-Clark saw immediate results, which included:

  • Better cut quality, particularly on the edges of the finished reels
  • Longer blade life
  • Easier knife holder dismantling and reassembly
  • Significantly quicker core handling and shaft puller cycle time
  • Significantly reduced need for manual operations
  • Increased operators’ safety

A.Celli’s configurations for the slitter rewinder upgrade 

When it comes to upgrading the slitter rewinder, A.Celli is the best choice. By relying on us, in fact, you have the possibility to choose from four different configurations:

  1. Manual positioning
  2. Manual positioning with a measuring device
  3. Automatic positioning web out (SLITTOMATIC®)
  4. Automatic positioning web in (SLITTOMATIC®)

Kimberly-Clark is just one example of what can happen when a company choose our upgrades. 

The end result, that is, a superior product manufactured in less time and higher productivity, will ultimately increase a company’s bottom line. Add to this an increased operator satisfaction and the slitter rewinder upgrade is well worth the investment.

If you want  to know more, contact us today for a free and non-binding consultation!

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Tissue and nonwovens mills rely primarily on the performance of their machinery to ensure the manufacturing of a high-quality product in a reasonable time and at optimal productivity. If this machinery is not running at peak efficiency or if it breaks down, production can slow down or stop altogether.

Yet, the equipment and machinery in a mill is subjected to extreme conditions on a daily basis. Machines in the mill are exposed to things like significant temperature variations and ongoing wear and tear that can impact their performance over time.

ACelli logoIn the past it was difficult, if not impossible, to detect small dips in machinery performance simply because the human eye can’t detect small changes in things like machine vibration or speed. By the time a lag in performance was noticeable, the machine was often already at a point of needing repair or would break down entirely. This is one of the biggest causes of lost productivity in the mill. Fortunately, with today’s technology, it is possible to perform real time analytics, allowing mill staff to know the performance level of their machinery at all times.

Measures of Machine Performance

Improving the performance and productivity of fixed assets is the best way to improve shareholder returns. Over the years, a number of key performance indicators (KPIs) have been developed to measure machine performance. Of these KPIs, Overall Equipment Effectiveness (OEE) has become an industry standard for the tissue and nonwovens mill.

OEE measures three categories within the mill: equipment availability, equipment performance, and product quality. When it comes to machine performance in the tissue and nonwovens mill, the focus is specifically on equipment availability, the amount of time the machine is actually up and running, and equipment speed.

While it is easy to see when a machine is running or not, it isn’t always easy to understand why it has stopped running or to see this downtime coming. When it comes to machine speed, it is not possible to detect small changes in that speed simply by looking at it. In the past, we simply did the best we could and dealt with machine downtime. However, today we have new technology that makes real time analytics possible.

The Role of Industry 4.0

Industry 4.0 is the key to ensuring optimal performance of mill machinery. It offers a combination of the Industrial Internet of Things (IIoT), data management, and artificial intelligence (AI)/machine learning that make it possible to continuously monitor every machine in every plant, as well as overall plant operations.

Pivotal to the measurement of machine performance in real time is IIoT. IIoT requires the installation of thousands of sensors and cameras along the production line. Every single machine will have dozens or hundreds of sensors that are continuously measuring every single aspect of the machine during operation. These sensors can gather data in a digital format from parts of the machine that mill workers cannot monitor adequately. They can sense changes in the machine’s operation that the human eye can’t even detect, all in real time.

The sensors on each machine are part of a company-wide network of sensors and devices that are connected to the cloud. As the data are collected, they are gathered and fed into AI software that can provide real-time analytics. Machine learning allows the machinery to make adjustments in real time and the system can alert staff of anomalous readings and let them know when maintenance is required.

A Bird’s Eye View with Real Time Analytics

How does all this improve machine performance? Since data are constantly flowing in from sensors sensitive enough to detect the slightest changes in machine performance, real time analytics:

  • provides a closeup view of the different variables affecting machine performance;
  • determines the probability that the machine will break down;
  • anticipates and schedules predictive maintenance.

In other words, when something isn’t working at peak efficiency and speed, the system will pick up on that. Maintenance can then be scheduled before those minor anomalies become big enough to cause the machine to slow down or break down entirely. In addition, with such detailed data from every part of every machine, a tissue and nonwovens mill can tweak environmental and machine settings to ensure the highest possible speed a machine can be run at without compromising product quality. This pushes machine performance to its optimal state, and when you can accomplish this, equipment availability and equipment speed scores increase and your overall OEE score goes up.

Final Word

The technology available today has made Industry 4.0 possible, and with that, real time analytics is also possible. With the ability to collect data continuously and while a machine is in operation, the chances of a machine going offline or slowing down are significantly reduced. This provides tissue and nonwovens mills with much tighter control over all aspects of their operations and allows them to automate their processes so they can increase operational efficiency and make better product with less waste and in less time. Since time is money, this is the ideal situation for any tissue and nonwovens company competing in the market today.

For more information about measuring machine performance in your tissue and nonwovens mill, please take a look at our eBook The Ultimate Industry 4.0 Guide for the Tissue and Nonwovens Market.

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The iDEAL® mod. 2000S Tissue Machine start-up took place on March, 20th in Mexico, perfectly in line, even in advance, compared to the challenging project scheduling and despite the very critical global conditions

The new A.Celli iDEAL® Tissue Machine machine has a 2650-mm web width, a working speed of 2000 m/min and a production capacity of about 100 tpd. It was designed to answer all the requests and demands made by Grupo Corporativo Papelera, who with this step forward made its strategic investment in the world of tissue paper production thanks to a high-performance machine.

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The scope of supply represents the state of the art of A.Celli technology, in particular with the following great innovations:

  • 16’ Forged Yankee, innovative and unique on the market, consisting of a single piece of steel heated to more than 1200 ° C, moulded and processed using forging and hot rolling systems, from which a cylinder of homogeneous material without welds is obtained.
  • Extreme Automation DCS System, completely new, intuitive and user-friendly that has allowed the customer to manage the machine autonomously from the very first day, always with the prompt remote assistance of A.Celli technicians.

The A.Celli team showed great flexibility, managing to complete a highly customized project on an engineering and assembly level.

Despite the very critical global conditions and with the extraordinary support and expertise of the Grupo Corporativo Papelera’s staff, the A.Celli team did not lose concentration, being able to manage the paper to the pope and make the first reel a few hours after the ignition.

With this new Tissue Machine A.Celli Paper will offer Grupo Corporativo Papelera a leap forward in quality, aiming for important and ambitious production milestones.

The long-standing competencies, dependable reliability and technological excellence that have always distinguished the Group make A.Celli Paper the ideal supplier for every customer.

Published in South American News

Kimberly Clark Products Malaysia, Kluang Johor Mill: A.Celli concludes the scheduled upgrade of the TM2 Tissue Line with a new off-line shaft puller and a new set of expandable spool, in combination with the upgrade of the rewinder slitting unit

After the upgrade of the TM1 rewinder and other tissue line equipment, A.Celli Papers Customer Service team installed and successfully concluded the upgrades on the TM2 tissue line.

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The intervention entailed updating the core handling system downstream the TM2 pope reel with the supply of the A.Celli off-line shaft puller. Since this an automated process, it allows the customer to improve and accelerate the shaft extraction from the mother roll and to improve KC Products Malaysia personnel safety. The rebuilding of the TM2 line has been completed with the upgrade of the Rewinder slitting section with a modern and efficient knives system.

A.Celli Paper worked in close contact with the customer, finding the optimal solution for a light-impact modification with a short shutdown time. The new configuration kept into consideration the convenience of the operations that had to be carried out on one hand and the needs of KC Products Malaysia on the other, in order to obtain the best results in terms of efficiency.

The customer was very appreciative of the project, acknowledging the high level of professionalism of A.Celli Paper’s Customer Service team and its ability to find functional, practical and intelligent solutions through engineering and design analyses.

A.Celli Paper is capable of offering prompt and effective consultancy in-line with any type of investment and production demand.

Contact us for a consultancy or a dedicated project.

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Last February 28, at the Chinese plants of SUNSHINE New Material for Hygiene and Health Care Jiangyin Co. Ltd. Located in Jiangyin, two machines for Spunlace product, a winder and a rewinder installed on two different lines side by side, have been started up.

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A.Celli supply, specifically tailored to the specific needs of the customer, includes:

  • E-WIND® STREAM Master Roll winder of 3600 mm capable of handling reels up to 2500 mm in diameter, with basis weights ranging from 30 to 100 gsm and with a maximum operating speed of 200 m/min, specifically designed for carded products and to guarantee maximum reliability and minimal maintenance
  • E-WIND® RAPID off-line slitter rewinder of 3600 mm, calibrated for reels with a maximum diameter of 1200 mm, with basis weights ranging from 30 to 100 gsm and with an operating speed of 800 m/min. Among the optionals we can find the "DSS" (defect stop system), a system able to monitor any defects on the reel, report them and give the possibility to remove them if necessary, and the “Slittomatic®”automatic slitting units positioning.

Once again, the long-standing expertise and experience of A.Celli Nonwovens and the particular attention to the customer have made possible the success of the project for the Chinese group SUNSHINE New Material for Hygiene and Health Care Jiangyin Co. Ltd.

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A.Celli Nonwovens SpA is honored to continue the fruitful collaboration with Karweb Nonwovens thanks to the supply of a winding line dedicated to the production of Spunlace

Karweb Nonwovens, a division of the KARA Holding Co. and one of the major player active in the production of Spunlace and Airlaid, has renewed, after a first order made in 2016, the trust in A.Celli and its cutting-edge solutions in the nonwoven market.

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The installation and start-up of the line, which will take place in the Turkish plant of Karweb Nonwovens located in Gaziantep, are scheduled for early 2021. A.Celli's supply includes a “Stream” Master Roll winder, an off-line slitter rewinder “Rapid” with an operating speed of 800m/minute and equipped with trim suction system, a shaft handling solution with "easy core" positioning device and a finished reel handling and packaging system.

A further confirmation of the customer's trust in A.Celli Nonwovens technology, that thanks to this supply proves, as always, to be at the cutting edge of the market and able to satisfy any type of requirement with flexibility and readiness.

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A.Celli developed the Dust Removal System with the aim of removing issues caused by dust loads in the slitting area

Nowadays dust issues are becoming more and more a prime concern, especially for hygienic fabric producers, high speed spunmelt production lines and other lines sensitive to the aforementioned issues, such as Spunlace, Airlaid and Meltblown ones.

In fact, dust deposition in the slitting area may reduce the cutting efficiency, contaminating the finished product and contributing to environmental pollution. In order to reduce the dust originated by the slitting processes in the rewinding section, A.Celli designed an efficient Dust Removal System.

A.Celli Dust Reduction System

This solution can be installed on in-line slitting winders, rewinders, spooling lines and printing lines, and it consists mainly of individual suction heads positioned on the knife holder and equipped with a blower system to remove dust accumulation on the knives. Other parts of the system are the suction line, a fan equipped with an inverter and a control unit, pipes and ducts to convey dust and air to the fan and a filter for dust/air separation.

There is also the possibility to add suction nozzles over the knives to increase the efficiency of the system.

The A.Celli Dust Removal System guarantees minimized dust loads on products and winders, expanded cleaning intervals, more production hours, the reduction of maintenance activities and the extension of the machinery useful life.

Furthermore, minimizing the dust in operational areas actually supports people’s health and safety.

Contact us for a consultancy or a dedicated case study

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