Super User

Super User

Kotkamills is a forest products company based in Kotka, Finland. The company specializes in consumer boards, laminating paper, and sawn products – and is an innovative pioneer in introducing new technologies. Kotkamills actively accelerates the adoption of plastic-free options in convenience packaging. The Sense condition monitoring system has been employed at Kotkamills from July 2019, ever since the first stages of the solution.

The system monitors the condition of the pumps in the pulp production line. The system monitors the condition of the pumps in the pulp production line.

The challenge

Kotkamills was one of the first customers to use Sulzer Sense in their process after it was launched in 2019. The system monitors the condition of five process pumps and one medium-consistency (MC) pump in the pulp production line.

The system consists of one gateway designed for industrial conditions, located in the process area, and six sensors installed in the bearings of the monitored equipment. The devices are battery-powered and operate in a wireless mesh network.

Sulzer Sense measures vibration and temperature every 30 minutes. The gateway is connected to the Internet / Sulzer’s cloud service via a cellular connection. The monitored devices are within a radius of about 10 meters from each other. This allows for an excellent network and the use of a single gateway.

The solution

The sensors are installed in the bearings of the monitored pumps.The sensors are installed in the bearings of the monitored pumps.The commissioning of the condition monitoring system was quick, easy and effortless and did not require special skills from the installer. The mobile app provided by Sulzer for the deployment of the system is unambiguous and easy to use.

The Sulzer Sense monitoring device measures machine vibrations and temperature to detect possible imbalance, misalignment, looseness, and bearing wear. It helps to identify changes in equipment condition parameters and indicates potential faults at an early stage, thus supporting predictive maintenance.

The cloud service provides the customer with easy access to device information. Through the cloud service, the customer can monitor the condition of the devices and view hardware trend information anywhere and anytime.

Customer benefit

  • In addition to the advantages of continuous monitoring, one of the most significant benefits to the customer is access to detailed equipment information such as spare parts lists and product documentation through the service. For maintenance and repair work, there is no need to look in the archive for instructions and drawings.
  • Sulzer Sense is suitable for all pumps, agitators, mixers and motors regardless of the type or brand in all industries.

"The system has worked reliably, and the measurement results are in line with our own reference measurements." Harri Carling, Supervisor, Condition Monitoring and Reliability at Kotkamills.

About Sulzer

Sulzer is a global leader in fluid engineering. We specialize in pumping, agitation, mixing, separation and application technologies for fluids of all types. Our customers benefit from our commitment to innovation, performance and quality and from our responsive network of 180 world-class production facilities and service centers across the globe. Sulzer has been headquartered in Winterthur, Switzerland, since 1834. In 2019, our 16’500 employees delivered revenues of CHF 3.7 billion. Our shares are traded on the SIX Swiss Exchange (SIX: SUN). The Pumps Equipment division specializes in pumping solutions specifically engineered for the processes of our customers. We provide pumps, agitators, compressors, grinders and screens developed through intensive research and development in fluid dynamics and advanced materials. We are a market leader in pumping solutions for water, oil and gas, power, chemicals and most industrial segments.

www.sulzer.com

Rugged field transmitter provides innovative functionality, improved measurement performance, and ease of use for applications in harsh environment conditions.

February 16, 2021 – Endress+Hauser launches iTEMP TMT142B, new generation smart temperature transmitter with Bluetooth. The transmitter delivers highly accurate and reliable measurements, wireless communication via Bluetooth, and user-friendly operation—all packaged in a robust single-chamber field housing. The technology offers significant improvements in process efficiency and plant availability while reducing costs.

2021 02 17 094556In industrial process engineering applications, temperature transmitters are an important link between temperature sensors in the process and the higher levels of automation. Measurement instruments are often installed in difficult-to-access locations, which frequently makes commissioning, operation and servicing more difficult.

To address these and other issues, the transmitter features a highly secure integrated Bluetooth interface that enables users to wirelessly visualize measured values, NAMUR NE 017 diagnostic information, as well as perform configuration tasks. The device is extremely easy and fast to operate using your phone or tablet and the Endress+Hauser SmartBlue app. No special tools required. Access to the device is password-protected, and Endress+Hauser security provisions for Bluetooth communication complies with the highest standards.

The newly developed backlit display provides excellent readability under all environmental conditions, both in the dark and bright sunlight. Diagnostic messages are highlighted when the normally white background turns red.

The conversion of different sensor signals into a stable, standardized output signal (4 to 20 mA) represents a logistical challenge as it often requires multiple transmitter variations. To meet this challenge, the configurable single-channel device transmits converted signals from resistance sensors (RTD), thermocouples (TC), resistances (Ω) and voltage transmitters (mV) via the 4 to 20 mA signal or the HART 7 communication.

iTEMP TMT142B temperature transmitter is designed for safe operation in hazardous areas as certified by international approvals (ATEX, CSA C/US, IECEx). Safe operation is enhanced by the incorporation of an integrated overvoltage protection that protects the device from damage and permits continued functionality after common upset events.

For more information visit https://eh.digital/3jN7Dsl.

About Endress+Hauser in the U.S.

Endress+Hauser is a global leader in measurement instrumentation, services and solutions for industrial process engineering. Endress+Hauser provides sensors, instruments, systems and services for level, flow, pressure and temperature measurement as well as analytics and data acquisition. We work closely with the chemical, petrochemical, food & beverage, oil & gas, water & wastewater, power & energy, life science, primaries & metal, renewable energies, pulp & paper and shipbuilding industries. Endress+Hauser supports its customers in optimizing their processes in terms of reliability, safety, economic efficiency and environmental impact. The Group employs nearly 14,000 personnel worldwide and generated [net sales of] more than 2.6 billion euros (2.89 billion U.S. dollars) in 2019.

The demand for flexible packaging materials is growing amid the transition towards sustainable food packaging. Walki has answered to this need by investing in a brand new flexo printing machine in its Jatne plant in Poland.

“This new investment will significantly increase our capacity and we will be able to answer to the fast growing demand in flexible packaging”, says Andreas Rothschink, Sales Director, Consumer End Uses at Walki.

The high-speeed machine is a 10-colour, state of the art flexographic printing machine that offers top quality and low change-over waste.  The investment includes a fully automatic plate mounting machine to further ensure superior printing accuracy on both paper and film and a system for fully automatic job setting in the printing machine. The inks used are water-based and hence environmentally friendly.

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As the food industry is shifting to recyclable food packaging, paper-based materials come up as a strong contender. The look and feel of the packaging  is an important differentiating factor for end consumers. This sets high demands on the print quality.

“The new flexoprinting machine assures great accuracy of the printouts and a very high quality”, says Jakub Gunert, Plant Manager in Jatne.

The importance of flexible packaging will grow substantially in the coming years as paper-based packaging is efficient both in terms of the amount of materials used and easy recyclability.

“With this investment we are strenghtening our capabilities to further improve the quality and efficiency in all of our product categories, ”, says Andreas Rothschink.

In addition to food packaging, the new machine in Jante will also serve ream wrapper customers.

For further comments, please contact:
Marko Siltala
Executive Vice President Industrial Packaging and Lean Operations
Tel. +358 40 585 2796
e-mail: This email address is being protected from spambots. You need JavaScript enabled to view it.

At Walki, we believe in a sustainable and circular tomorrow. Our mission is to accelerate the world’s transition into a zero waste future in packaging and promote the use of energy efficient materials across industries. Walki’s product solutions are designed to bring value to customers in many different markets; from sustainable materials for packaging applications to energy saving performance materials. Walki is a growing international group organized in three business areas: Consumer Packaging, Industrial Packaging and Engineered Materials, with operations in twelve different countries, both in Europe and Asia. In 2019, the Group’s annual turnover was approx. 400 million euros employing around 1000 people.

walki.com

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. 

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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.

For further information, please contact:
Gian Luca Fornesi, Head of Sales Application, Toscotec Paper & Board division, This email address is being protected from spambots. You need JavaScript enabled to view it.

Digitalization with data integration between various systems will optimize efficiency in production planning, reduce waste and improve customer service.

GS Paperboard & Packaging Group (GSPP), one of the largest players in the domestic containerboard segment and the integrated paper and packaging manufacturers in Malaysia, has chosen TietoEVRY as their business transformation partner. Digitalization with data integration between various systems will optimize efficiency in production planning, reduce waste and improve customer service. The renewal is based on TIPS industry solutions and services for the pulp, paper, board, packaging, tissue, and non-woven industries.

2020 06 05 111601GSPP has three paper machines and three corrugated carton plants. The modernization of operations increases company's overall efficiency, especially production planning between the paper machines to reduce waste. Digitalization and automation also increase the company’s competitiveness in the growing Southeast Asia market e.g. by enabling more accurate demand forecast.

“Digitalization is an on-going process in GSPP, but the knowledge of how to integrate new technology into our existing systems to improve company efficiency is a big ask. The solution from TietoEVRY not only answers this question, it also lays the foundation for GSPP digitalization initiatives for the future,” says Yeoh, Kheng Leong, Senior Manager, IT, GSPP.

“We are proud to continue our long-term collaboration with Malaysian GSPP mill in their transformation journey. By selecting TIPS, the company can enhance their overall business performance and deliver improved customer service. The business renewal also offers GSPP a competitive edge and the added benefit of improved sustainability,” says Carsten Henke, Head of Pulp, paper and fibre at TietoEVRY. 

TietoEVRY creates digital advantage for businesses and society. We are a leading digital services and software company with local presence and global capabilities. Our Nordic values and heritage steer our success.

Headquartered in Finland, TietoEVRY employs around 24 000 experts globally. The company serves thousands of enterprise and public sector customers in more than 90 countries. TietoEVRY’s annual turnover is approximately EUR 3 billion and its shares are listed on the NASDAQ in Helsinki and Stockholm as well as on the Oslo Børs. www.tietoevry.com

GS Paperboard & Packaging Sdn Bhd (GSPP), a member of Oji group, has been a dominant player in the domestic containerboard segment and they are one of the largest integrated paper and packaging manufacturers in Malaysia, founded in 1992. www.gspp.com.my

The data and inventory management of products and consumables involves a considerable amount of administrative work. The new digital asset management tool OnCare.pmPortal now offers paper manufacturers an optimum alternative for increasing both the transparency of product data and the efficiency of the procurement system, while also facilitating the planning of maintenance periods and downtimes and increasing plant availability. Thanks to a direct connection to the Voith Paper Webshop, registered components can be reordered quickly, easily and without any risk of confusion. 

  • Maximum transparency of product data, run times and inventories
  • Optimally planned maintenance periods and downtimes
  • Rapid reordering of registered components via the Voith Paper Webshop

“With the OnCare.pmPortal, Voith has developed a powerful asset management tool that simplifies central data management and gives paper manufacturers an overview of key products and consumables in their paper machine,” says Richard Birkhold, Global Product Manager Asset Management at Voith. “This facilitates optimized documentation of activities such as maintenance, repair and replacement, and simplifies data maintenance.” A particularly convenient feature of this tool is that it allows employees to select the component they are looking for using a digital image of the paper machine and provides them with immediate access to all relevant product information.

“Every day, I coordinate maintenance measures and control numerous processes,” says Karl-Josef Uhlemann, maintenance manager for rolls at Schoellershammer in Germany. “With the digital inventory management tool, I can now manage consumables and rolls centrally and access the data at any time and from any place.” 

The OnCare.pmPortal now starts with two modules: The automated data recording of rolls and fabrics, as well as the digital inventory management of doctor blades. These product groups are automatically identifiable in the OnCare.pmPortal by means of a digital nameplate and do not require manual entry in the system. 

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ID tagging for rolls and fabrics: For constant visibility of product data and run times
The ID tagging module for rolls and fabrics is a combination of contactless, radio-based connection technologies and the integration of digital nameplates based on proven industry standards. The solution offers simple, user-friendly tagging of rolls and fabrics and enables seamless identification through the scan of a digital nameplate. Regardless of the technology standard, the ID tags can be read with a smartphone and the corresponding Voith app and managed in the OnCare.pmPortal. The mobile application grants access to all product data, at any time and from any location, for efficient tracking of the product history and optimized documentation of activities such as maintenance, repair and replacement. 

Karl-Josef Uhlemann explains: “Thanks to the combination of OnCare.pmPortal and the ID tagging module, I can identify a product directly via the digital nameplate or search the database. The mobile application with its intuitive interface provides a quick and easy overview of product information and important product lifecycle data.” 

Blade Inventory Management System: Digital control of inventory data and fully automated management of inventories
With the help of the Blade Inventory Management System module, the operator no longer has to worry about ordering doctor blades or the associated stock control and supply chains. This is made possible with an ID tag on the packaging of the doctor blades. New doctor blades are automatically reordered and delivered by the system as soon as the stock in the warehouse reaches a minimum, individually defined level. As soon as the new blades arrive in the customer warehouse or existing blades are removed from the warehouse, the stock is updated in the OnCare.pmPortal and can be accessed from there at any time, thus increasing inventory traceability and transparency. At the same time, there is no need to maintain inventory lists or carry out inventory controls. As a result, the OnCare.pmPortal not only reduces the outlay and costs associated with inventory management, but also increases its efficiency by using automated and digitized processes. 

Voith plans to extend ID tagging to additional consumables and components in the near future and, in doing so, will offer paper manufacturers an even more powerful tool.

Further information on the OnCare.pmPortal and available modules can be found at: www.voith.com/oncarepmportal 

About the Voith Group
The Voith Group is a global technology company. With its broad portfolio of systems, products, services and digital applications, Voith sets standards in the markets of energy, oil & gas, paper, raw materials and transport & automotive. Founded in 1867, the company today has more than 20,000 employees, sales of € 4.2 billion and locations in over 60 countries worldwide and is thus one of the larger family-owned companies in Europe.

The Group Division Voith Paper is part of the Voith Group. As the full-line supplier to the paper industry, it provides the largest range of technologies, services and products on the market and offers paper manufacturers holistic solutions from a single source. The company’s continuous stream of innovations facilitates resource-conserving production and helps customers minimize their carbon footprint. With its leading automation products and digitalization solutions from the Papermaking 4.0 portfolio, Voith offers its customers state-of-the-art digital technologies to improve plant availability and efficiency for all sections of the production process.

Mondi, a global leader in packaging and paper, has successfully developed a new recyclable functional barrier paper range. Designed with protection in mind, this range of certified recyclable barrier paper solutions is fully integrated across Mondi’s value chain—from paper production to the barrier application—and can run on existing filling lines for form-fill-and-seal (FFS) applications.

Mondi’s AegisPaper range reduces the amount of plastic used by replacing it with a renewable resource that has specific mechanical properties, such as puncture resistance, flexibility, printability and barrier protection. The coatings technologies applied to these papers create custom barriers against grease and water vapour and ensure sealability. AegisPapers are suitable for numerous packaging applications within the dry food, frozen food, pet food, confectionery, secondary packaging, toy, e-commerce, flower packaging, and DIY industries.

MNDPR173a

The functional barrier paper can replace plastic packaging that has traditionally been used for FMCG and consumer products. In a first step, Mondi’s collaboration with a European dry pasta producer will reduce the plastic used by 90% and save them 7,5 tonnes of plastic film per year for one of their product ranges. This pasta packaging and other commercialised solutions will be entering the market in the first half of 2021.

“Sustainability is at the centre of our strategy and I am pleased that this continues to be a focus for our customers. Thanks to combining Mondi’s know-how of paper making, coating, printing, converting, pouch and bag making alongside our expertise in selected end-uses for consumers, we make ‘paper where possible, plastic when useful,’ a reality. This launch is a breakthrough for the next generation of sustainable packaging.” said Peter Orisich, CEO, Flexible Packaging and Engineered Materials, Mondi.

Within AegisPaper, there are three grades available for different applications and requirements:

  • AegisPaper select offers a wide range of custom barrier properties
  • AegisPaper 95/5 food is certified as fully recyclable and has the best mechanical properties for food applications
  • AegisPaper reduce provides the thinnest functional barrier paper to reduce amount of packaging material needed

The paper and coatings are all produced and applied in Europe.

Read more about Mondi’s range of recyclable barrier papers, AegisPaper, here: www.mondigroup.com/aegispaper

FreeForm Packaging is launching a new, stretchable, paper laminate based on 85% paper. The new laminate is considered to be “one-sided”, which has been highly requested by many brand owners and retailers. Called Standard Paper Out, it does not have the traditional polythene layer on the outside – instead, it has paper. This gives any FreeFormPack® a natural, warm feel. 

FreeForm Packaging produces and sells the world’s first truly formable paper packaging solution, based on stretchable and printable paper-based laminates that you can shape, twist and emboss, along with the unique machines that produce FreeFormPack®. Up until now, FreeForm Packaging has only been able to offer laminates with polythene on both sides to ensure good sealing properties, but this has now changed. A new process enables the packages to be fully sealed and makes it possible to shape them as required. The new laminate still offers good WVTR values, although it is less effective than a double-sided laminate.

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“This is like a dream come true,” says Danevert Åsbrink, CEO of FreeForm Packaging AB. The new laminate allows the FreeFormPack system to produce formable paper packaging that is pleasant to the touch, which customers have been wanting for a very long time. “We have been working hard on this for the last six years, so it feels almost unreal to have finally reached our goal,” adds Danevert.

The FreeFormPack Standard Paper Out laminate has two layers of FibreForm®, and one of its two sides has a thin layer of polyethylene that protects the contents while also protecting the packaging. Considering the increased focus in society on recyclability, the emergence of the new laminate has been perfectly timed.

FreeForm Packaging AB is a Swedish company owned by CURTI (Italy) and BillerudKorsnäs AB (Sweden). With the FreeFormPack® Machine by CURTI and the FreeFormPack® Laminate, based on FibreForm® from BillerudKorsnäs in Sweden, the company offers customers more environmentally sound packaging compared to plastic.

Metsä Board launches a development programme for its white-top kraftliner mill in Kemi, enabled by Metsä Fibre's new bioproduct mill investment announced today. The development programme is a significant step towards the company's sustainability targets for 2030. Metsä Board and Metsä Fibre are parts of Metsä Group. Metsä Board owns 24.9 per cent of its associated company Metsä Fibre.

The development programme will increase the mill's annual paperboard capacity by approximately 40,000 tonnes. The programme includes a series of modernisation and bottleneck investments in the paperboard production line, and as part of the programme, Metsä Board will purchase the modernised unbleached pulp production line with an annual capacity of approximately 180,000 tonnes from Metsä Fibre in 2023. The total investment value of the programme is approximately EUR 67 million, divided in 2021–2023, and mainly in 2023.

logoThe development programme will reduce the Kemi paperboard mill’s water consumption by about 40 per cent and energy consumption by about 5 per cent per tonne of paperboard produced. Metsä Board's company-level target is to reduce water consumption by 30 percent and energy consumption by 10 percent per tonne of paperboard produced by 2030 compared to 2018.

Metsä Board’s annual net surplus in pulp will increase by approximately 325,000 tonnes in 2023, consisting of Metsä Board's 24.9 per cent share of Metsä Fibre's new bioproduct mill’s capacity increase, the transfer of the unbleached pulp production line to Metsä Board's direct ownership and the impact of the increased paperboard capacity on pulp consumption.

Financing for Metsä Fibre's bioproduct mill consists of funds generated from operations and debt. Metsä Board does not invest equity in Metsä Fibre to finance the project. Metsä Fibre will record an impairment loss impacting the result in the first quarter of 2021 related to the old pulp mill in Kemi. The impact on Metsä Board’s share of Metsä Fibre’s result is estimated to be approximately EUR -8 million and it will be classified as an item affecting comparability.

“Demand for premium and recyclable white-top kraftliners is growing rapidly in our main markets in North America and Europe. After these investments, Metsä Board's leading position in coated white kraftliners globally will be further strengthened, and Metsä Fibre's new bioproduct mill together with Metsä Board's paperboard mill will form a world class integrate in Kemi, Finland. The investment will significantly reduce water and energy consumption at the Kemi paperboard mill, and bring us closer to our ambitious sustainability targets, which we have set for year 2030. This also supports our customers' sustainable business,” says Mika Joukio, CEO of Metsä Board.

Metsä Board 

www.metsaboard.com 

Metsä Board is a leading European producer of premium fresh fibre paperboards and forerunner in sustainability. We produce premium lightweight folding boxboards, food service boards and white kraftliners for consumer goods packaging as well as retail-ready and food service applications. We work together with our customers on a global scale to innovate solutions for better consumer experiences with less environmental impact. The pure fresh fibres Metsä Board uses are a renewable resource, traceable to origin in sustainably managed northern forests. We aim for completely fossil free mills and raw materials by 2030.  

The global sales network of Metsä Board supports customers worldwide, including brand owners, retailers, converters and merchants. In 2019, the company’s sales totalled EUR 1.9 billion, and it has approximately 2,400 employees. Metsä Board, part of Metsä Group, is listed on the Nasdaq Helsinki. 

Metsä Group

www.metsagroup.com

Metsä Group is a forerunner in sustainable bioeconomy utilising renewable wood from sustainably managed northern forests. Metsä Group focuses on wood supply and forest services, wood products, pulp, fresh fibre paperboards and tissue and greaseproof papers.

In 2019, Metsä Group’s sales totalled EUR 5.5 billion, and it employs approximately 9,300 people. Metsäliitto Cooperative is the parent company of Metsä Group and is owned by approximately 100,000 Finnish forest owners.

Among the main features of quality Tissue paper there are certainly a high bulkiness and softness. How can this be achieved by using a conventional configuration with a single press nip and, at the same time, decrease energy consumption? The answer is our A.Celli X-Roll solution.

The demands of the Tissue industry

Tissue paper producers all over the world are constantly looking for solutions that allow them to offer high quality products without possibly increasing production costs, among which those linked to energy consumption certainly stand out. In fact, as highlighted in the previous article about water management in a Tissue plant, we recall that the final evaporation eliminates a relatively small part of the total water present in the fibers, but involves a considerable waste of thermal energy supplied by steam boilers (for the operation of the Yankee Dryer) and by an aerothermal system.

With this in mind, a series of studies conducted on pilot lines led to the conclusion that the key to obtaining the best results in terms of bulk without negatively affecting consumption could be represented not so much by the pressing phase that takes place in the nip between the suction press roll and the Yankee Dryer, but from the previous pre-drying phase carried out by means of the suction sector of the press roll itself located immediately before the nip.

The results of the studies described above show, in fact, that a significant impact on the output of the production process is due to the degree of dryness of the felt and, therefore, by the ability of the latter to absorb water from the Tissue paper. Starting from this, A.Celli has developed a solution to optimize the configuration with a single press nip in order to obtain Tissue paper of equal quality and, at the same time, a reduction in energy consumption associated with the drying area.

Conventional configuration with a single press nip

Let's analyze the operation of a conventional Tissue machine with a single press:

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In this case, the pressing that takes place in the nip formed by the suction press roll and the Yankee Dryer will be contextual to the action of the vacuum sector inside the suction press roll itself. The latter consists of a perforated cylinder equipped with a metal shell and covered in synthetic material, and the holes have the task of retaining the water drained by the pressing action. Inside the shell there is a suction box whose task is to create a depression inside the press itself by connecting to a vacuum pump, thus sucking the air present in the holes in order to allow the water to be housed inside them. This water will then be extracted by centrifugation as soon as the effect of the vacuum itself disappears..

In this configuration it is also possible to use a steam box, positioned in correspondence with the suction press roll and just before the nip, whose purpose is to increase the water temperature and therefore decrease its viscosity. In this way, during the pressing phase the water is able to flow better into the felt and into the holes of the suction press roll.

However, the positioning of the steam box is not optimized from the point of view of efficiency as it acts in a point where the Tissue paper still has a high amount of water. In addition to this, the case thus positioned is subject to clogging due to the fiber fragments expelled by centrifugal force from the felt during the passage on the suction press roll. The consequence is that these fragments, once the steam box is activated, will be thrown at high speed against the Tissue paper, causing breakages.

A.Celli X-Roll 

As we have said, A.Celli X-Roll's goal is to combine the quality of Tissue paper obtainable using the traditional configuration with a lower total energy consumption.

To achieve this result, the goal was to ensure a high degree of dryness of the felt before the pressing phase, so as to reduce the power to be supplied in the drying section during the subsequent evaporation phase. While the conventional configuration first envisages the combined action of the steam box and the vacuum followed by the action exerted by the nip, A.Celli X-Roll uses in succession a suction roll, a steam box and a blind press:

  • In the first place we will have the action of vacuum by means of the suction roll. By doing so, a part of water will be eliminated, thus increasing the degree of dryness of the felt before the next two phases.
  • In this way the steam box, positioned between the suction roll and the press nip, and a flat vacuum box will act in a point where the felt has already been partially dried by the previous process, increasing the temperature of the sheet more efficiently and eliminating the risk of clogging of the steam box itself.
  • Finally, the action of the nip between the Yankee Dryer and the blind press will ensure that the sheet proceeds towards the evaporation area of the Tissue machine with a high degree of dryness and with the same bulkiness obtainable using a conventional configuration.

In terms of energy savings, we were able to detect, from tests performed on a pilot line, that the A.Celli X-Roll solution leads to a 4% increase in the degree of dryness of the paper exiting the pressing process compared to the conventional configuration,which translates into an energy saving of over 16% in the drying phase.