Displaying items by tag: Toscotec
The AHEAD 2.2 tissue machine supplied by Toscotec to Cartiera Confalone is operating at the maximum speed and is largely exceeding its guaranteed production capacity. After start-up of this turnkey tissue line in September 2021, Toscotec has followed through supporting Cartiera Confalone to optimize the process and achieve top performances.
Valter Di Nardo, Chief Customer Service Officer of Toscotec, says, “Considering the soaring costs of energy here in Italy, our service team has worked closely with Cartiera Confalone to maximise the drying performance of the machine by fine-tuning TT NextPress and TT Hoods to take full advantage of the cogeneration system. Toscotec also went the extra mile to provide the mill’s new staff with the best training: our papermaker has consistently worked with their production department on site and all our specialist have been assisting onsite or remotely as needed.”
With more than 20 projects since 2015, Toscotec is the global leading supplier of turnkey tissue plants. Part of its responsibility as turnkey supplier is the continuous assistance to achieve the guaranteed performance and the fine-tuning of the tissuemaking process.
Gaetano Confalone, Sole Director of Cartiera Confalone, says, “The great cooperation between our team and Toscotec stands behind today’s results. Together we have executed this project in the midst of the Covid-19 pandemic, and we wouldn’t be here today if it weren’t for our joint efforts to achieve excellence on this new line both in terms of tissue quality and production capacity. We appreciated Toscotec’s expertise and flexibility throughout this whole journey together.”
Riccardo Gennai, Sales Manager of Toscotec, comments, “Toscotec has a long-standing partnership of more than 20 years with Cartiera Confalone. In 1999, we installed their first tissue line at Maiori mill. A decade later, we proposed to replace PM1’s cast-iron Yankee with Toscotec’s most updated technology, our leading-edge TT SYD Steel Yankee Dryer. We have always worked together as trusted partners, and we will continue on this path in the future.”
About Cartiera Confalone
With origins dating back to 1800 when a paper mill producing handmade paper was set up in Maiori, Cartiera Confalone made flattened and creped paper until the 1970s when production was converted to tissue. It is a family-run manufacturer of toilet tissue, kitchen roll, napkins, and jumbo rolls, distributing both in Italy and in international markets.
Voith and Toscotec will participate in the 54th ABTCP International Pulp and Paper Exhibition, to be held on October 4-6 at the Transamerica Expo Center, in São Paulo.
The Voith Group’s booth will be showcasing the company’s innovative solutions to the paper industry and will include the broad portfolio of its subsidiaries Toscotec and BTG.
At 10:30 am on October 6, Sales Director of Toscotec Brazil, Marcos Scheil, will give the lecture “Solution to Decarbonize the Drying Process in Tissue Manufacturing”.
Also, Wellington Vieira, Tissue Sales and Applications Manager at Voith Paper South America, will present the poster “New Measurement Technologies Providing In-Depth Analyses of Tissue Pressing Section”.
Focused on the topic “Pulp and Paper, Environment, Society, Governance and Automation”, the ABTCP International Pulp and Paper Exhibition is an opportunity for exchanging best practices that can help all industry players increase their productivity and efficiency.
For more information on schedules, registration fees and how to participate, visit: abtcp2022.org.br/programacao/.
54th International Pulp and Paper Exhibition
Date: October 4-6, 2022
Venue: Transamérica Expo Center
Address: Av. Dr. Mário Vilas Boas Rodrigues, 387 - Santo Amaro, São Paulo - SP
Since its foundation in 1948, Toscotec specializes in the design and manufacture of turnkey projects, complete machines, plant rebuilds and single equipment for the tissue and paper & board industries.
Headquartered in Lucca, with affiliates and service centres in China and North America, Toscotec provides state-of-the-art technology and customized solutions to leading paper producers around the world. From 30th April 2020, Toscotec is part of the Voith Group.
Toscotec will sponsor Pianeta Terra Festival, a celebration of sustainability in all its shapes and forms running from 6th to 9th October in Lucca, Italy. Organized by publisher Laterza and directed by internationally renowned plant neurobiologist and author Stefano Mancuso, this first edition of the festival offers insightful conferences, talks, and joyful night music, featuring multidisciplinary experts and creatives. Sustainability is explored far and wide to offer a 360-degree view that spans from ecology to literature, sociology, economics, finance, art, nutrition, and more.
The festival’s mission is to encourage a new connection with the natural environment and make space for creativity and conversations around the theme of sustainable living.
Alessandro Mennucci, CEO of Toscotec, says: “Supporting a purpose-driven festival on sustainability here in Lucca was an opportunity we just could not miss. We hope many people will join us in discovering new angles to this far-reaching and multi-faceted subject, so crucial in today’s world.”
The program of Pianeta Terra Festival is online: https://www.pianetaterrafestival.it/
For more information, please contact:
Toscotec will showcase technological breakthroughs designed for the paper mill of the future at MIAC 2022 from 12th to 14th October in Lucca, Italy.
Toscotec has developed two paper drying innovations aimed to cut direct greenhouse gas emissions to zero. TT Induction SYD, a revolutionary Steel Yankee Dryer design using electrical induction to dry paper, and TT Hydrogen Burner, a new generation of 100% hydrogen-fueled burners for Yankee hoods.
At MIAC Conferences, Toscotec will present:
- Tissue Conference, 12th October: Elena Troia, Energy & Environment Sales Manager, will illustrate how renewables-powered technology can deliver the highest production while slashing emissions, with a presentation titled “Breakthrough tissue innovations for sustainable drying”.
- Paperboard Conference, 14th October: Giancarlo Gianlorenzi, Sales Manager Toscotec Paper & Board and Oliver Thomas, Sales Manager Voith, will talk about “Papierfabrik Niederauer Mühle’s rebuild case study” presenting Voith and Toscotec’s joint PM2 rebuild project for German paper manufacturer Papierfabrik Niederauer Mühle.
Contacts to book an appointment at Toscotec’s booth 109:
Vajda-Papír has chosen Voith Paper and Toscotec’s digital documentation platform OnCare.eDoc for the comprehensive and user-friendly management of all the technical information of its new tissue line. On 6 July 2022, Vajda-Papír has started up an AHEAD 2.2L tissue machine supplied by Toscotec on a full turnkey basis including the complete production line and all auxiliary systems.
Zoltan Pataki, Operations Director at Vajda-Papír, says, “The OnCare.eDoc platform contains the entire scope of supply of our new line. It is very easy to pull any type of technical document such as manuals, drawings, and process flow diagrams. Easy access to specific information allows us to increase operation and maintenance efficiency. With this flexible platform we can finally say goodbye to hours spent searching for documents and data”.
OnCare.eDoc delivers a clear user guidance and easy-to-use structure both from desktop and from portable devices. As a key advantage, it includes all the technical documentation of the entire paper mill, so that any equipment supplied by Toscotec and Voith can be sourced in one single point. Due to the large amount of collected data, OnCare.eDoc also offers an effective search function for all kinds of documentation needs.
“Efficiency and digitalisation go together. In the future Toscotec’s technical documentation will be delivered on OnCare.eDoc. Our goal is to provide customers with a clear and easy-to-manage digital documentation platform. On a large supply such as Vajda-Papír’s turnkey project, we are confident that OnCare.eDoc will make the difference” comments Lorenzo Melani, Documentation Technical Coordinator at Toscotec.
Henrik Tallowitz, Strategic Product Manager Webshop at Voith Paper, adds: “Many customers from us benefit from the advantages of OnCare.eDoc. With customized functions such as a favorites list, paper manufacturers can sort their documentation according to specific requirements. This can minimize future search efforts.”
For more information, please contact:
Vajda-Papír started up a double-width AHEAD 2.2L tissue machine supplied by Toscotec (PM2) at its Dunaföldvár facility in Hungary. The supply was full-on turnkey, including the entire tissue production line and all erection operations at the mill.
A complete turnkey supply
The turnkey scope included the entire stock preparation system and Toscotec’s patented TT SAF® (Short Approach Flow) fitted with a double dilution system to maximize energy savings. It comprised 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.
For the mill’s PM1, Toscotec also supplied an OPTIMA 2600 slitter rewinder equipped with automatic shaft puller and dust removal system that came online in February 2022.
Toscotec’s turnkey scope included a complete service package with detailed mill engineering, erection, training, commissioning, and start-up assistance. The installation of this double-width tissue line required a substantial erection team of more than 190 technicians over a period of approximately 200 days.
A tissue machine designed for superior energy efficiency
The AHEAD 2.2L machine features a net sheet width of 5,600 mm, a maximum operating speed of 2,200 m/min, and a production capacity of over 80,000 tons/year. It is equipped with Toscotec’s state-of-the-art technology, including a fully hydraulic TT Headbox-MLT, a shoe press of the upgraded design TT NextPress, a third-generation TT SYD Steel Yankee Dryer, and TT Hood system designed for maximum energy recovery.
Attila Vajda, Managing Director of Vajda-Papír, says, “This new Toscotec line constitutes our flagship investment at Dunaföldvár site. We have a vision for Vajda-Papír’s expansion to be in harmony with the environment, and that is why we chose the most energy efficient technology available on the market. Throughout the entire project, the whole Toscotec team demonstrated their extensive expertise and great passion for tissuemaking. The successful start-up of PM2 represents a key achievement and an important step forward for Vajda-Papír’s sustainable growth.”
Gabriele Barattini, Toscotec Project Manager, says: “Successfully completing a turnkey project of this magnitude is a great satisfaction indeed. The cooperation with Vajda-Papír’s team has been excellent all along and has allowed us to manage every phase in the best possible way. Toscotec’s flexibility is crucial for the success of any project, even more so for turnkey projects.”
About Vajda-Papír Ltd.
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 115,000 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 Hungary and over 30 countries worldwide.
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Toscotec, the global market leader of Steel Yankee Dryers, introduces TT Induction SYD, a carbon-reduction breakthrough that redefines Yankee dryer technology entirely. TT Induction SYD uses electrical induction instead of steam energy to dry the paper web, thereby cutting direct greenhouse gas emissions to zero.
In 2000, Toscotec pioneered a major technological innovation, TT SYD, the first Yankee dryer entirely made of steel. Steel Yankees have since surpassed their cast-iron equivalent to become the benchmark for drying efficiency and safety in the paper industry. TT Induction SYD is now set to be the new game changer in tissue for its capability to use clean energy and slash direct carbon emissions associated with the drying process.
A disruptive innovation for dry crepe and TAD tissue machines
With TT Induction SYD, the internal steam distribution and steam/condensate removal systems are entirely replaced by an induction system composed of static coils installed inside the shell and electrical controls and instrumentation located outside for easy maintenance and monitoring. As a result of precise coil geometry, the induction system delivers a very fast and accurate heating effect exactly on the areas of the shell where it is required, while preventing residual circulating currents in other areas.
Steam-heated Yankees use steam energy typically generated by burning fossil fuels. TT Induction SYD uses electrical energy that can be derived from renewable energy sources while delivering the same result, i.e. uniformly heating up the Yankee’s shell in contact with the paper web to achieve dryness. TT Induction SYD is suitable for installation on dry crepe as well as Through-Air-Drying (TAD) tissue lines.
Luca Ghelli, Toscotec R&D Director, says, “Sustainability is the guiding idea of TT Induction SYD’s design. As a proven industrial technology, an induction system offers multiple advantages when applied to the most energy-intensive section of the tissue machine. The efficiency of this cutting-edge technology will dramatically reduce the carbon footprint of papermaking. Based on our expertise in steam-heated TT SYD and induction systems, we succeeded in developing a more efficient and sustainable steel Yankee dryer.”
Substantial carbon reduction with unchanged productivity and paper quality
Normally, approximately half of the carbon dioxide emissions produced by a tissue machine originate from the operation of the Yankee dryer. By using clean energy, TT Induction SYD achieves zero direct emissions, while maintaining productivity unchanged and reducing energy consumptions because of the higher efficiency of the induction system. Due to the precise heating of the shell, it also eliminates possible moisture profile issues related to uneven condensate removal, thereby ensuring an improvement in moisture uniformity in both cross direction (CD) and machine direction (MD).
Maximum safety, easier operation, and maintenance
TT Induction SYD was designed without any electrical, mechanical, and radiation risk to ensure maximum safety. Besides offering safe operations, it also clears all issues related to the maintenance of steam-heated Yankees, including pressure vessel’s mandatory and planned controls, maintenance of condensate straw pipes against potential plugging and of special heads for steam and condensate inlet and outlet. The entire Yankee system is simplified in the absence of steam: the heads, the internal surface which is groove-less, and the steam and condensate auxiliary system disappears entirely, including the steam generator with related maintenance and controls and delicate controls for steam quality. TT Induction SYD simply requires relatively easy maintenance on the electromagnetic induction system.
For further information, please contact:
Toscotec launches INGENIA, a new concept tissue machine to produce premium quality structured tissue paper. The quality generated by INGENIA line is substantially higher than textured tissue and close to Through Air Drying (TAD) produced paper, but using 35% less energy.
With INGENIA Toscotec responds to the challenge of today’s paper market calling for premium quality tissue obtained with lower energy use and lower capital investment than TAD lines. INGENIA’s concept is based on consolidated technologies for premium tissue, building on vast internal know-how of Toscotec’s and Voith’s R&D, and field data validation on TAD and structured paper systems.
Paolo Raffaelli, Toscotec Chief Technology Officer, says: “The key factor for energy reduction compared to TAD, is that INGENIA achieves significantly higher dryness through non-thermal dewatering on a structured moulding fabric. With TAD, the thermal drying starts from 24-26%, whereas INGENIA achieves a much higher dryness level without using hot air or steam. This maintains the premium quality obtained through rush transfer and structured moulding fabric, but uses much less energy.”
Ultra-premium tissue quality
Through non-compressive water removal technologies and efficient fiber moulding, INGENIA produces much higher tissue quality properties than other technologies for textured or conventional DCT tissue. These properties include bulk, softness, stretch, and absorbency, which improve the tactile “hand” feel and the final paper characteristics that compete with premium segments for toilet, facial and towel tissue grades.
The specific pattern of the structured fabric and the use of a calender can further enhance the quality of end products.
Energy Efficiency through Process Innovation
The process of this new concept machine begins with a dilution profiling layered TT Headbox-ML operating on a twin-wire forming section. Like TAD machines, INGENIA operates wire rush transfer at low consistency, but its key capability is an enhanced vacuum de-watering system without pressing the paper web, which ensures that dryness is greatly increased while fibers are being supported in the same shape as they originally formed when fully water saturated.
At the end of the wet section, TT NextPress shoe press uses low loading pressure to gently stabilize the web dryness content and transfer the paper to the drying section without bulk compression. The combined action of a third-generation design TT SYD Steel Yankee Dryer and high-efficiency TT Hood achieves the final desired dryness.
The process is completed by dry creping, sheet stabilization integrated with dust removal, and precision winding using an electro-mechanical TT BulkyReel fitted with a Center Wind Assist on the primary and the secondary arms. The Center Wind Assist fully preserves bulk by reducing the nip pressure against the reel drum during the winding process.
The new INGENIA offers top flexibility, as it can easily swing from the production of premium quality structured tissue to conventional DCT. When in conventional mode, INGENIA delivers top machine speed and production capacity.
INGENIA features widths up to 6 m, a production capacity from 100 to 250 tpd, and operating speeds up to 1,500 m/min in structured tissue mode or 2,000 m/min in conventional mode, depending on machine size and customer requirements.
For further information, please contact:
Specialty paper manufacturer Cartiere di Guarcino selected Toscotec for the rebuild of PM2 at its Guarcino paper mill near Frosinone in Italy. The project is scheduled for December 2022.
The rebuild consists of the modification of the paper machine’s forming and press sections with installation of both Toscotec’s and Voith’s technology. In the forming section, the supply of a customized breast roll and Voith’s FloatBearings will substantially enhance paper formation by boosting the performance of an existing shaking unit. Secondly, the installation of Voith’s EdgeMasters on the forming wire will deliver optimal paper web edge. Finally, the rebuild of the Fourdrinier section will be completed by a new wire stretcher and tail cutting unit.
In the press section, Toscotec will supply an additional press nip with associated felt run, the overhauling of the hydraulic system, and a technological doctoring system equipped with savealls to improve water removal. PM2’s press rolls will be equipped with polyurethane covers customized by Voith for each position: an AquaFlow cover on the first nip to minimize shadow marking and a SolarPress cover on the second and third nips to optimize dewatering. The service package of the rebuild includes erection supervision, commissioning, and start-up assistance.
The project has a twofold purpose of enhancing paper quality and increasing production capacity. By ensuring the shaking system’s efficient operation, the rebuild will increase fibres orientation in cross direction and deliver a more homogeneous distribution. This will result in better formation and improved paper quality. The modification of the press section will boost post-press drying rate, leading to a production increase.
Simone Principia, Plant Manager of Cartiere di Guarcino, says: “This investment fits into the growth strategy of Neodecortech Group. Cartiere di Guarcino is set to increase production performance through a fully customized technological solution. We aim to raise the bar on product quality and achieve the utmost differentiation in the high-end market of decor papers.”
Enrico Fazio, Sales Director of Toscotec’s Paper & Board division, says: “On this new project, we have achieved a very strong synergy with Voith and were able to meet the favour of Cartiere di Guarcino by including both Toscotec’s and Voith’s highly technological solutions. In the spirit of great flexibility that defines Toscotec, we devised a tailor-made solution for their unique and demanding market segment. Cartiere di Guarcino certainly has all the papermaking skills to realize the full potential of our technology.”
About Cartiere di Guarcino S.p.A.
Cartiere di Guarcino, part of Neodecortech Group, is an Italian manufacturer of decor specialty papers operating a production facility in Guarcino, Frosinone. It specializes in high quality products for application in office and home furniture and laminate flooring, including unicolours, print base papers, backer papers and underlays. In line with its sustainability-focused strategy, the paper mill uses electrical and thermal energy produced by Bio Energia Guarcino, a carbon-free cogeneration plant fuelled by animal fats and vegetable oil residues.
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Toscotec has successfully renewed its ISO 14001 certification and Eco-Management and Audit Scheme registration for environmental protection and is on track to obtain the ISO 45001 certification validating a significant improvement in occupational safety. Toscotec has been complying with these stringent environmental standards for 16 years, attesting to its consistent commitment to sustainability.
Besides pursuing sustainable operations, Toscotec is proud to advance the decarbonization of the paper industry by designing and manufacturing energy efficient technology and services that significantly reduce the energy demand of the paper making process and preserve natural resources such as water and fibres.
Validated improvements in sustainability
Toscotec is the only tissue machinery manufacturer in Italy to participate in the Eco-Management and Audit Scheme (EMAS) devised by the European Commission. EMAS constitutes a premium benchmark for environmental management, as it sets forth demanding guidelines that voluntarily registered organisations comply with to improve their green performance, credibility, and transparency. Toscotec’s environmental management system is also certified to ISO 14001 since 2005.
In addition, Toscotec is strictly implementing an occupational safety management system, which includes key policies and objectives driving the improvement of health and safety at work in compliance with the ISO 45001 international standard. This set of actions demonstrates a complete, effective, and fully integrated HSE (Health, Safety, Environment) management system.
“Toscotec has confirmed an ever-growing commitment to corporate sustainability with notable improvements in energy efficiency and waste management capacity. To name a few examples, since 2011 at our headquarters facility, we have been abandoning halogen and fluorescent lamps for LED lights, a move that has reduced our electrical consumption from illumination by 40%.” says Andrea Marzaro, Toscotec’s Operations Director (COO). “For heating, we replaced fuel oil boilers with natural gas boilers equipped with state-of-the-art burners that have both cleared the issue of fuel oil disposal and increased our energy efficiency. In the space of green energy, we have made significant progress in energy self-generation at our main production site and have progressively replaced diesel-fuelled forklifts with new electric ones.” adds Andrea Marzaro.
Toscotec has been generating electric power from solar energy for more than 10 years. Through four implementation phases, it stepped up its photovoltaic system by over 360 kWh, of which 260 KW/h are used for the internal demand of Toscotec’s manufacturing operations and 100 KW/h are sent back to the grid. Since 2011, by generating more than 3,500 MW/h of renewable energy, Toscotec’s photovoltaic solar plant has saved more than 1,800 tons of CO2 emissions into the atmosphere.