Displaying items by tag: Toscotec

Toscotec will supply an entire dryer section rebuild to Hamburger Turkey, part of the Hamburger Containerboard Group, at their paper mill in Çorlu in Northern Turkey. The project focuses on their containerboard machine (PM3) and is planned for the end of 2024. 

Targets: production increase and basis weight range expansion 
The rebuild has two main targets. Firstly, the replacement of the existing cast-iron dryer cans with Toscotec’s custom-sized TT SteelDryers will increase the sheet drying width by 90 mm while maintaining the same face length and using the existing machine frame. This will lead to an increase of PM3’s production capacity. 
The second target is to expand the basis weight range and produce lower grammages to enter a new market for lighter testliner products through an improvement in the wet section. 

The scope of supply 
Toscotec will supply thirty seven TT SteelDryers for a full upgrade of the dryer section and new TT UniRoll vacuum rolls in the first dryer group. The scope also includes all the mechanical drives and doctor blades of the dryer section. Toscotec will also upgrade PM3’s press section and the sheet stabilization system from the press to the second dryers’ group. The service package includes the erection supervision, training, commissioning, and start-up assistance. 

Hamburger Turkey’s paper mill in Çorlu (Turkey). Hamburger Turkey’s paper mill in Çorlu (Turkey).

Faik Ozturk, Project Manager at Hamburger Containerboard, says, “Our cooperation with Toscotec began in 2020 when we purchased our first TT SteelDryer. This new rebuild is part of an important market strategy. It will bring great results with minimal intervention because it maintains the non-technological components of the machine. Therefore, we will realize the complete upgrade of PM3’s dryer section in an easy and cost-effective way.”  

Fabrizio Charrier, Sales Manager of Toscotec’s Paper & Board division, says, “I’m very proud to have reached this agreement with Hamburger Containerboard in Turkey. Toscotec’s customized technology precisely meets the needs of this project. This order also comes from an efficient and professional approach during the technical analysis phase. I’m confident that this synergy will lead to a long-term cooperation with their group on future projects.”

About Hamburger Containerboard Group 
Hamburger Turkey, part of the Hamburger Containerboard Group, is a leading manufacturer of high-quality corrugated base paper. It has two production facilities: in Çorlu and in Denizli, where it manufactures corrugated case material products. The Hamburger Containerboard Group, part of the Austrian Prinzhorn Holding, dates as far back as 1853. With 10 locations in 5 different countries, the group has a total production capacity of more than 3 million tons/year, which comprises brown and white uncoated papers, white coated papers, and plasterboard.

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South African tissue producer Jumbo Centre has started up an AHEAD 1.8 tissue line supplied by Toscotec at their Johannesburg facility. This is a repeat order for Toscotec after the successful installation in 2020 of another complete tissue machine at the same mill. 

The AHEAD 1.8 machine has a sheet trim width of 2,750 mm, an operating speed of 1,800 m/min and a production capacity of more than 30,000 tpy. It is equipped with a new generation design TT NextPress shoe press, a third-generation TT SYD Steel Yankee Dryer, and high-efficiency TT Hood. The scope of supply covers the complete production line from the bale handling and stock preparation systems to the electrification and control system of the tissue machine. The associated services include detailed engineering, erection supervision, commissioning, training, and start-up. 

Itzik Nikfard and Rafi Nikfard, Directors of Jumbo Centre, said, “This investment marks a new important stage of expansion for our business. The choice of technology is key in supporting the continuous growth and success of our SnowSoft brand. Toscotec’s machines deliver premium tissue quality, high production efficiency, and energy savings which equip us to succeed in the market.” 

Jumbo Centre and Toscotec’s teams at Jumbo Centre’s mill in Johannesburg, South Africa. Jumbo Centre and Toscotec’s teams at Jumbo Centre’s mill in Johannesburg, South Africa.

Sean Nieuwenhuys, Chief Operating Officer, remarked, “I have been acquainted with Toscotec for several years and been involved in the start-up of three tissue machines with Toscotec as the key technology provider and partner. Toscotec is known for fulfilling its technological commitments and helping clients achieve its efficiency and quality goals. I am confident that with this latest project, our business will reap the benefits of numerous technological advancements and improved energy efficiency. We anticipate that the new generation shoe press will enhance the bulk and softness of our products and improve the overall efficiency in our converting operations”.

Matteo Giorgio Marrano, Toscotec Sales Manager, says: “Toscotec is proud to support Jumbo Centre in their decision to continuously upgrade their tissue making technology over the years to properly support their growth in the regional market. They moved from simple machinery to our energy-efficient MODULO-PLUS machine and now to this state-of-the-art AHEAD tissue line featuring Toscotec’s best-in-class energy efficiency technology. An impressive journey in just a few years’ time.”
 
About Jumbo Centre (Pty) Ltd
Since 1999, Jumbo Centre manufactures and sells high quality Tissue Paper in South African and in the regional market. 

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Europap Tezol Kağit started up a Toscotec-supplied AHEAD 2.2 tissue machine at its integrated production facility in Mersin, Turkey. The new high efficiency line started producing high quality tissue immediately after start-up. The project also included two OPTIMA slitter rewinders, with the first already in operation, and the second scheduled for installation soon. This is a repeat order for Toscotec who also installed a TT SYD Steel Yankee Dryer on their PM1 in 2012. 

The AHEAD 2.2 line features a sheet trim width of 2,920 mm, an operating speed of 2,100 m/min, and an annual production capacity of over 40,000 tons. It is equipped with Toscotec’s upgraded design TT NextPress shoe press, a third-generation TT SYD, TT BulkyReel for optimal preservation of bulk and softness, and high efficiency TT Hood with the automatic balancing system TT DryingEquilibrium. 

The supply included the complete stock preparation system, Toscotec’s patented TT SAF® DD (Short Approach Flow system with Double Dilution) to ensure electrical consumption reduction, as well as electrification and controls, and dust and mist removal systems. Toscotec delivered a comprehensive service package with detailed engineering, erection supervision, commissioning, training, and start-up assistance.  

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Ahmet Şenyaşa, Factories Director at Europap Tezol Kağit, says, “The cooperation with Toscotec during the entire project was very positive. We are confident that this state-of-the-art tissue line will allow us to meet the high quality standards of our customer base, especially in terms of the softness and hand feel of our super-prime brands.”

Matteo Giorgio Marrano, Sales Manager at Toscotec, says, “The high energy efficiency of this tissue machine is ensured by the combination of Toscotec’s latest generation design of TT NextPress and TT SYD with TT Hoods equipped with automatic balancing system. Europap Tezol will reap the benefits of this advanced technology both for energy savings and superior quality. With this successful project, Toscotec takes a further step in strengthening its presence in the EMEA market.”  

About Europap Tezol Kağıt 
Established in 2000, Europap Tezol is a major manufacturer in the Turkish tissue market, and it operates three tissue mills in Turkey with integrated converting, in Torbali-Izmir and in Mersin-Tarsus. The annual capacity is 93,000 tons and it will be increased to over 133,000 tons with this new line. The company distributes its branded and private label tissue products, including toilet tissue, paper towels, and napkins, not only in Turkey, but also in many other parts of the world. 

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Graphic paper manufacturer Les Papeteries de Clairefontaine started up PM6 after a dryer section rebuild supplied by Toscotec at its Etival Clairefontaine mill in France. The machine produces graphic paper in the basis weight range from 60 to 100 gsm. 

The project was focused on PM6’s pre-dryer section for which Toscotec supplied TT SteelDryers designed for an operating steam pressure of 10 barg, as well as an upgrade of the machine frame. The associated services included the complete erection with supervision, commissioning, and start-up assistance. 

The rebuild has achieved the target of increasing PM6’s drying face length without changing the overall width of the machine frame. 

PM6’s dryer section at Les Papeteries de Clairefontaine’s Etival Clairefontaine mill in France. PM6’s dryer section at Les Papeteries de Clairefontaine’s Etival Clairefontaine mill in France.

Julien Courant, Production Engineer at Les Papeteries de Clairefontaine, says, “The project had a positive outcome. We have enhanced our paper quality by improving the moisture profile in cross direction.”

Giancarlo Gianlorenzi, Sales Manager at Toscotec, says, “Through the cooperation with a well-established player such as Les Papeteries de Clairefontaine, Toscotec strengthens its presence in the French market. We were very happy to support the mill in the coordination of the project. Based on our vast experience in dryer section rebuilds, we are well positioned to continue serving this market area effectively.”

About Les Papeteries de Clairefontaine
Les Papeteries de Clairefontaine is a subsidiary of the Exacompta-Clairefontaine group, which is comprised of over fifty companies and employs over 3,200 staff, including 580 people at Les Papeteries de Clairefontaine. They are a well-established market player and produce a wide range of office and graphic papers. 

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Toscotec will supply a complete rebuild of PM1’s drying section to Rexcell Tissue & Airlaid at its Skåpafors mill in Sweden. Planned for the second half of 2024, the project aims to support Rexcell to achieve substantial energy consumption reductions as part of its strong commitment to sustainability. 

Energy Saving Customized solution
Toscotec will supply a customized solution designed to deliver substantial gas consumption reductions, as well as a significant increase in machine run-ability.
The scope includes a press section upgrade, a latest generation TT SYD Steel Yankee Dryer with new steam and condensate system, and a high efficiency TT Hood with a complete air system. The latter features various steps of heat recovery and an advanced BMS (Burner Management System) to optimize combustion efficiency through precise control of the combustion air, where the burners are fit to make an efficient use of LPG first and biomethane in the near future. The hood plant is also equipped with TT Drying Equilibrium, a reliable system that automatically regulates the air balance in the hoods, thereby ensuring maximum drying efficiency, faster basis weight changes, and a production increase. 

Rexcell Tissue & Airlaid’s production facility at Skåpafors in Sweden. Rexcell Tissue & Airlaid’s production facility at Skåpafors in Sweden.

Two-fold target
The rebuild aims to considerably reduce PM1’s thermal energy consumption through the use of state-of-the-art drying technology designed for energy efficiency, and to increase the machine speed and production capacity in the future. 

Lars Andersson, CEO at Duni Rexcell, comments, “At Rexcell we take global environmental challenges very seriously. As a part of Duni AB, we share the same vision to be Net Zero 2030 along with considerable energy reductions. This machine upgrade is a strategic investment that perfectly fits into this vision. Toscotec’s energy efficient technology will take us a step closer to realizing maximum energy savings and minimal material footprint.”

Riccardo Gennai, Sales Manager at Toscotec, says, “It is a pleasure for Toscotec to cooperate with Rexcell who is on track to operationalize its transition from fossil-based to fossil-free sources. By developing a customised solution for the new drying section of their PM1, we will ensure the highest possible energy efficiency, as well as substantial energy savings compared to the present configuration.”

About Rexcell Tissue & Airlaid AB
Rexcell, a wholly owned subsidiary of Duni Group, operates one of the most advanced paper mills in Europe for the production of specialised tissue. Located in Skåpafors, Sweden, the mill started production in 1898 with their first paper machine. Through continuous innovation, today Rexcell produces Airlaid, Tissue and Evolin products in a variety of colours.

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Lucart has selected Toscotec for the complete rebuild of PM14’s Yankee hoods and air system at their Aranguren tissue mill in Spain. The project is scheduled for the first quarter of 2024. 

Tailor-made solution for drastic consumption reduction
Based on an onsite survey conducted to verify the existing system’s performance, Toscotec developed a customized solution designed to deliver gas consumption reductions exceeding 30%, as well as a significant increase in machine run-ability.
The scope includes a high efficiency, gas fired TT Hood-Duo system, which ensures a perfectly uniform Cross Direction (CD) moisture profile. The new air system features low-emission burners, several stages of energy recovery, and Toscotec’s TT Swing, a patent pending solution that delivers maximum flexibility and energy savings in regulating the air system operation mode. By switching between a parallel and a hybrid configuration based on production needs, TT Swing guarantees optimal energy efficiency in the drying section of the tissue machine.

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Luca Bini, Paper Mill Project Engineer at Lucart, comments, “We selected Toscotec because they proved their ability to dig deep and offer an efficient solution to the root causes of our problem, instead of patching up the old system. Based on our long cooperation, we are confident they will deliver the best possible outcome for Lucart both in the short and the long term.”

Elena Troia, Energy & Environment Sales Manager at Toscotec, says, “Lucart has quickly validated our technical offer, because of the substantial consumption reductions we can guarantee and Toscotec’s strong expertise in energy saving solutions. With this level of savings, we were able to guarantee a ROI of less than 2 years.” 

Long standing partnership
Lucart and Toscotec have a long established cooperation. Toscotec installed a complete tissue line (PM12) in 2018 at their Porcari mill, as well as 4 rebuilding projects including a hood and air system rebuild (PM4) in 2016, and 3 TT SYD Steel Yankee Dryer installations in France and Italy as replacements of cast iron Yankees in 2016, 2019 and 2020. 

About Lucart 
Lucart is a multinational group that promotes a sustainable way of making paper. This is achieved by adopting a systemic approach designed to optimise the use of raw materials and reduce waste by turning them into new resources. Lucart makes airlaid, MG paper, and many tissue products (toilet paper, kitchen paper, napkins, tablecloths, handkerchiefs, etc.). The production activities of the company founded by the Pasquini family in 1953 are organised across three Business Units (Business to Business, Away from Home, and Consumer), engaged in the development and sale of products with brands, such as Tenderly, Tutto, Grazie Natural, and Smile (Consumer market) and Lucart Professional, Fato, Tenderly Professional, and Velo (Away from Home market). The production capacity is over 396,000 tonnes/year of paper on 12 paper machines. The consolidated turnover is over EUR 700 million and 1,700 people are employed at 10 production plants (5 in Italy, 1 in France, 1 in Hungary, 2 in Spain and 1 in the UK) and a logistics hub. Lucart joined the United Nations Global Compact Network Italy in 2020 and has been awarded a “Platinum” sustainability rating by the independent certification company Ecovadis.

Contact
Elena Troia
Energy & Environment Sales Manager, Toscotec
Email: This email address is being protected from spambots. You need JavaScript enabled to view it.

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Toscotec has renewed its sponsorship of Pianeta Terra Festival, a far-reaching dive into Sustainability running from 5th to 8th October in Lucca, Italy. Following the vastly successful first edition of 2022, the festival organizers, the publisher Laterza and its director, prominent plant neurobiologist and author Stefano Mancuso, have decided to focus this second edition on the theme of “The Network of Life”, i.e. the dense, ingenious network that binds together all living creatures.  

Sustainability is explored from a multidisciplinary perspective that spans across ecosystems, climate, new economic models, energy, agriculture, food, urban development, but also new political, social, philosophical, anthropological, and artistic visions. The festival sets out to disseminate knowledge and prompt conversations around the theme of Sustainability, as well as promote a deeper understanding of our close interdependence with Nature.

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“We are happy to renew our support for Pianeta Terra Festival among the great anticipation we are witnessing of its return to Lucca this October” says Alessandro Mennucci, CEO of Toscotec. “We look forward to seeing the festival hit a new record-high in public turnout, with people from our province as well as visitors joining in and reverberating the discourse on this crucial subject.” 

The program of Pianeta Terra Festival is online: www.pianetaterrafestival.it  

Contact
Giulia Fabbri 
Sustainability & Communication Senior Manager 
Email: This email address is being protected from spambots. You need JavaScript enabled to view it. 

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Shawano Specialty Papers, a division of Little Rapids Corporation, started up a TT SYD Steel Yankee Dryer supplied by Toscotec at their paper mill in Shawano, Wisconsin, USA. It replaced an existing cast iron dryer on PM3. 

Technological advantages
(From left to right): Michael Drage, President of Toscotec North America, and Michael Bogenschutz, Vice President and General Manager of Shawano Specialty Papers in front of PM3 at Shawano facility in Wisconsin, USA. (From left to right): Michael Drage, President of Toscotec North America, and Michael Bogenschutz, Vice President and General Manager of Shawano Specialty Papers in front of PM3 at Shawano facility in Wisconsin, USA. The new TT SYD has significantly increased PM3’s production capacity and is ensuring higher operation safety. Compared with the replaced cast iron Yankee, it is delivering substantial energy savings, which reduce the overall operating costs of the tissue machine. 

Indisputable market leadership 
Toscotec holds a large majority of the global market share of Steel Yankee Dryers boasting more than 260 TT SYD sold worldwide. Since its first Steel Yankee started up in 2000, TT SYD has been installed in every corner of the globe. It is now present in more than 45 countries across 5 continents, with a stronghold in Europe where it holds close to 95% of the market share. With this successful start-up, it strengthens its position in the USA as undisputed Steel Yankee market leader.

Michael Bogenschutz, Vice President and General Manager of Shawano Specialty Papers, says “Toscotec provided excellent technical support throughout the entire project. Start-up of the new Yankee went smoothly, and the dryer is performing well. We are experiencing lower energy consumption and are seeing the potential for increased production efficiency.”

Michael Drage, President of Toscotec North America, Inc., says, “Our latest-generation design Steel Yankee delivers the highest possible drying efficiency in the tissue industry, which is of course a deal breaker for any tissue producer. We are happy to see that with this TT SYD Shawano Specialty Papers has gained a key competitive advantage to support their growth in North America.”  

About Little Rapids Corporation
Founded by Charles Egan in 1947, it remains a family-owned business. The company’s core product lines serve the medical and beauty market segments, flexographic printing for a variety of packaging markets, and tissue, MG paper, and wet crepe paper for the specialty paper market. The company proudly employs over 450 people in its Green Bay and Shawano, Wisconsin locations. 

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Toscotec will supply a forming section rebuild of PM2 to Gulf Paper Manufacturing at their Mina Abdullah paper mill in Kuwait. PM2 machine produces tissue from 100% virgin fibres, and it is scheduled for rebuild at the end of 2023. This is a repeat order for Toscotec who in 2019 successfully delivered a major dryer section rebuild of Gulf Paper’s packaging paper machine (PM1).

The project aims to improve PM2’s paper formation and basis weight cross direction (CD) control through an approach flow system upgrade and the installation of a state-of-the-art TT Headbox. The new headbox will be designed to match the high quality requirements for facial tissue in the Middle Eastern market.

Toscotec and Gulf Paper Manufacturing (GPM) at Paper One Show in UAE (from right to left): Marco Dalle Piagge, Sales Director Tissue Toscotec; Fabio Bargiacchi, Sales Manager Toscotec; Tareeq Al Moasherji, CEO GPM; Ghaleb Alhadhrami, Projects & Development Manager GPM; Ahmed Kasim, Plant Manager GPM; Enrico Fazio, Sales Director P&B Toscotec.Toscotec and Gulf Paper Manufacturing (GPM) at Paper One Show in UAE (from right to left): Marco Dalle Piagge, Sales Director Tissue Toscotec; Fabio Bargiacchi, Sales Manager Toscotec; Tareeq Al Moasherji, CEO GPM; Ghaleb Alhadhrami, Projects & Development Manager GPM; Ahmed Kasim, Plant Manager GPM; Enrico Fazio, Sales Director P&B Toscotec.

Ghaleb Alhadhrami, Gulf Paper Manufacturing Projects & Development Manager, says, “With Toscotec’s rebuild of our packaging paper machine in 2019, we achieved a substantial production increase, reduced sheet breaks by over 80%, and improved paper quality especially in the moisture profile and hand feel. We are confident that Toscotec will deliver on this new upgrade of our tissue machine as successfully as they did two years ago. This new headbox and approach flow system are also fit for a future rebuild into crescent former configuration.”

Fabio Bargiacchi, Sales Manager at Toscotec, says, “A rebuild is always a challenge, as it requires strong engineering skills, experience, and flexibility. We are delighted that our tailor made solution was selected for this project. Our technology will support Gulf Paper to improve product quality and strengthen their tissue business. Toscotec consolidates its position in the Middle East, which includes 4 projects for super-soft facial tissue production awarded over the last two years.”

About Gulf Paper Manufacturing
Established in 1978, Gulf Paper Manufacturing was the first company to start manufacturing paper in the Gulf region in 1981. Owned by two families of Kuwaiti entrepreneurs, it operates three production lines at its Mina Abdullah paper mill in Kuwait: PM1 produces packaging grades, mainly Fluting medium, Test liner and white top liner, using 100% recycled paper; PM2 manufactures tissue from 100% virgin pulp; the third is a tissue converting line. The company’s current capacity is 70,000 tons, with 70% of its packaging grades being destined for export to GCC (Gulf Cooperation Council) countries and chiefly Saudi Arabia, and the domestic market accounting for approximately 30% of its business.

Contact
Fabio Bargiacchi
Sales Manager, Tissue division Toscotec
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Egyptian linerboard manufacturer ETAP started up PM2 at its Borg Elarab mill, following a press section rebuild successfully carried out by Toscotec. PM2 produces testliner, kraftliner, top kraftliner and white top in the range from 125 to 240 gsm. In 2018, the machine had already been modified by Toscotec who entirely rebuilt its Fourdrinier wire section in stainless steel.  

Toscotec successfully replaced an existing plain press in the first part of PM2’s press section with a new bi-nip concept press, which has achieved a two-fold target. First, the increase of post-press dryness; and second, an efficiency increase of the entire press section through a substantial reduction of paper breaks. 

Mohamed Ashour, Managing Director at ETAP, says: “On our second major rebuild with Toscotec, we are once again very satisfied with their ability to effectively manage the project from inception to completion. ETAP has increased its production capacity taking advantage of Toscotec’s advanced technology.” 

ETAP and Toscotec teams during the start-up of PM2 at ETAP mill in Egypt: (from left to right) Marco Del Chiaro, Project Manager Toscotec; Vedran Simic, Mechanical Supervisor Toscotec; Mohamed Ashour, Managing Director ETAP; Sameh Habib, CEO Chemitex Egypt for Trading & Agencies; Luca Nesi, Design Engineer Toscotec; Flavio Biondi, Automation Supervisor.ETAP and Toscotec teams during the start-up of PM2 at ETAP mill in Egypt: (from left to right) Marco Del Chiaro, Project Manager Toscotec; Vedran Simic, Mechanical Supervisor Toscotec; Mohamed Ashour, Managing Director ETAP; Sameh Habib, CEO Chemitex Egypt for Trading & Agencies; Luca Nesi, Design Engineer Toscotec; Flavio Biondi, Automation Supervisor.

“ETAP is an important customer for Toscotec in Egypt and in the Middle Eastern market” comments Enrico Fazio, Sales Director Paper & Board division Toscotec. “We had a very positive cooperation four years ago, and we are very satisfied to carry on our collaboration with this project and to continue supporting them with Toscotec’s expert services in the future.” 

Sameh Habib, CEO at Chemitex Egypt for Trading & Agencies S.A.E., says, “The partnership with ETAP has been successful for over two decades and we are very proud to contribute again to ETAP’s growth by successfully landing their latest rebuild in collaboration with Toscotec. We look forward to more success with upcoming projects.”  

About ETAP
Established in 1990, ETAP is a family business that has grown to become one of the leading manufacturers of high quality linerboard in Egypt. Its production facility is located in Borg Elarab, Alexandria, where it operates two paper machines with an annual production capacity of approximately 120,000 tpy. Their product range includes top kraftliner and testliner1 that are distributed in the local and export markets. 

Contact
Enrico Fazio
Sales Director, Paper & Board division Toscotec
Email: This email address is being protected from spambots. You need JavaScript enabled to view it.

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