Displaying items by tag: Toscotec

Juthor Paper Manufacturing, part of MEPCO Group, has started up a complete tissue line including an AHEAD 2.2L tissue machine and two OPTIMA slitter rewinders supplied by Toscotec on a turnkey basis at its new tissue mill in KAEC, Saudi Arabia. With this start-up, MEPCO, a leading containerboard manufacturer, effectively enters the tissue market. 

The turnkey supply
The scope includes the entire tissue production line from cellulose bale handling to the wrapping and labelling of the finished wound jumbo rolls. The double-width AHEAD 2.2L line features a maximum design speed of 2,200 m/min and an annual production capacity of over 60,000 tons. It is equipped with a shoe press TT NextPress of upgraded design, a third-generation TT SYD Steel Yankee Dryer, and high efficiency TT Hood-Multigen with integrated cogeneration air system. The two OPTIMA 2600L slitter rewinders ensure the preservation of superior bulk and softness. 

Efficient tissuemaking with a Combined Heat and Power production (CHP)
The AHEAD machine is perfectly integrated with the mill’s CHP system, in order to tap on its secondary heat production to meet the thermal energy needs of the tissue production line. The drying section of the machine uses the CHP-produced thermal energy to both generate steam to use in the Steel Yankee Dryer and to achieve the correct drying temperature of hot air circulating in the Yankee hoods air system. As a result, the tissue machine will rely entirely on the CHP system for paper drying and will not require any additional gas consumption and associated greenhouse gas emissions. 

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Adel Alfar, Operations Director at Juthor, says, “Our partnership with Toscotec has been marvellously successful. Even though we faced some challenges during the pandemic, we have successfully managed to deliver the test run and the commercial launch according to the scheduled timeline very smoothly and efficiently, producing premium quality tissue products.”

Stefano Raffaelli, Project Manager at Toscotec, says, “We are extremely happy of the positive outcome of this project. With a strong commitment to the project’s targets, we have overcome the global logistical challenges encountered during the pandemic and kept our focus on our shared goal of putting this state-of-the-art tissue line into operation. We are confident that the mill will benefit from its superior efficiency and paper quality right away.”

About MEPCO
MEPCO is the leading vertically integrated paper manufacturer in the Middle East, offering a diverse range of containerboard and specialty paper products serving the packaging, construction, furniture, and paper core industries around the world. MEPCO supplies its products to the local Saudi market, as well as the GCC, Middle East and Africa. The Company’s innovative approach to doing business enables it to deliver significant environmental and economic benefits to Saudi Arabia. MEPCO is listed on the Saudi Stock Exchange (Tadawul) under symbol ‘1202’. 

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Toscotec has successfully integrated its spare and wear parts portfolio into the Voith Paper Webshop. Customers can now order products quickly and easily around the clock using the latest functions. The Voith Paper Webshop has been operating for over six years and is constantly advancing to increase user-friendliness. Since June, Toscotec has onboarded more than 20 projects covering 3 multinational corporations.

The Webshop ensures easy consultation: users can access all the information they need on spare and wear parts in just a few clicks. It also allows for integration into the mill’s ERP (Enterprise Resource Planning) system so that customers can use their internal codes when planning for and purchasing spares.

Toscotec’s Webshop team (from left to right): Lorenzo Bonino, Spare Parts Technical Coordinator; Lorenzo Melani, Documentation Technical Coordinator. Toscotec’s Webshop team (from left to right): Lorenzo Bonino, Spare Parts Technical Coordinator; Lorenzo Melani, Documentation Technical Coordinator.

Lorenzo Bonino, Spare Parts Technical Coordinator at Toscotec, says, “On one single platform, customers can both access their technical documentation and purchase spare parts. Information is made available for an entire paper mill, so that the staff of that production site can find everything in one place: topic-based and E-learning training, maintenance and operation manuals, as well as spare and wear parts for all their Toscotec equipment.”

Lorenzo Melani, Technical Coordinator of Toscotec Documentation Department, comments, “The Webshop saves time to the technical and administrative staff who search and purchase spares. They can access it from pc or tablet, and it allows for a much more quick, easy and efficient way to perform these tasks.”

Contact
Toscotec Spare Parts department
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Toscotec has successfully launched a new digital online Training Center, which offers in-depth and continuously updated technical information and user-friendly education tools. The onboarding of 10 tissue producers was completed in only three months. 

Based on Voith’s web portal, the new Training Center has been fully developed and operationalized by Toscotec. The responsible team composed of Pietro Morrica (Training Technical Manager and Sales Support), Lorenzo Melani (Technical Coordinator), and Gabriele Belli (Technical Writer), answered a few questions to point out its key features.

What does the Training Center offer?
Pietro Morrica: First and foremost, it offers immediate access to a very comprehensive set of technical information anytime and on any device. It gives customers on-demand learning tools for their new technology so that they can promptly and independently learn about and resolve many problems that require expert knowledge to fix whenever they occur. 

Toscotec’s Documentation team (from right to left): Pietro Morrica, Training Technical Manager and Sales Support; Lorenzo Melani, Technical Coordinator; Gabriele Belli, Technical Writer. Toscotec’s Documentation team (from right to left): Pietro Morrica, Training Technical Manager and Sales Support; Lorenzo Melani, Technical Coordinator; Gabriele Belli, Technical Writer.

What kind of training can you find in the Training Center?
Pietro Morrica: Both topic-based Training Presentations and animated E-Learning Video Procedures for all tissue mill equipment from Stock Preparation, Main Machine, Support Sub Systems, all the way through Finished Roll Handling after Rewinders. The topic-based Training Presentations gives easy to understand explanations of the technical and functional concepts of Toscotec’s supplied equipment, how to set up the equipment properly, so those concepts work during operation, as well as in depth mechanical and electrical maintenance details of the various systems. Let’s take for instance the Shoe Press, a user will find all information relating to its mechanical structure and working theory, the hydraulic P&ID diagrams with explanations of the lubrication system components and function, its DCS operation (the tilt and all settings and adjustments), troubleshooting guides, and so on. In brief, all things Shoe Press from any point of view are included and easily accessible. 

What about the E-learning part? 
Lorenzo Melani: The E-Learning part is specifically designed for maintenance purposes, as it uses both animations and recorded video/pictures of actual equipment to clearly show each step of various maintenance procedures of the complex electro-mechanical automation systems. Firstly, being web-based, it can be accessed from any kind of device - pc, tablet, phone, or even augmented reality glasses/visor – on the mill floor while directly in front of the equipment. Secondly, operators can watch the video procedure they need to perform while doing it; they can simply play and pause the procedure as they go along. Finally, it is custom and all-inclusive, in the sense that Toscotec will work directly with a customer to develop whatever they will need and give suggestions according to our experience so all the information they need will be there. Before, maintenance operators worked with static mechanical assembly drawings, which required experience and advanced mechanical skills but don’t offer any electrical and automation detail. Or they had static procedures that gave limited sense of exactly which actions are needed. With Toscotec’s E-Learning, we go from that level of abstraction and compartmentalized information to the reality of on demand, in the field, motion demonstrated, access to any information (mechanical, electrical, and control-related) in an easy to follow and immediate manner. 

What does continuous update mean and why does it matter?
Gabriele Belli: Toscotec custom develops the training using the project specific 3D drawings of its technology in order to guarantee that the information given matches the actual machine installed at the mill. For operators and maintenance personnel on site, it is vital that the user manual, the topic-based Training Presentations and E-Learning are spot on to what’s actually in front of them. We are in charge of continuous information updates in the Training Center, and it is a task we carry out daily. If there is an engineering change in the field, we can easily adjust the online material to match. So anytime someone goes online to view the information, the person is assured they are accessing the absolute latest and greatest design version.

Contact
Lorenzo Melani
Technical Coordinator, Documentation Department Toscotec 
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UNIPAKHELLAS Central (UHC), a member of INDEVCO Group, have started up a paper machine and a slitter winder delivered by Toscotec as the main machinery supplier at their Pelasgia mill in Greece. The new line (PM5) is manufacturing high quality test liner and fluting grades for the Greek and international markets. 

PM5 has a wire width of 3,000 mm, a maximum operating speed of 800 m/min and produces corrugated paper in the range from 90 to 200 gsm using 100% waste fibres. It features a two-layer Fourdrinier configuration with a hydraulic TT Headbox-SL. It is equipped with Toscotec’s shoe press TT Xpress, TT SteelDryers in the dryer section, as well as a hard nip calender, a hydraulic pope reel and the tail threading system. The scope is completed by mechanical drives, an enclosed hood, and air and ventilation systems. INDEVCO, through its engineering company Phoenix, realized all the auxiliary plants. 

Imad Issa El Khoury, Executive Vice President of INDEVCO Paper Making, says, “This was great teamwork between INDEVCO, Toscotec and other European collaborators during the pandemic to achieve successful results and a promising future for UNIPAKHELLAS.” 

UNIPAKHELLAS Central and Toscotec’s teams at UHC paper mill in Pelasgia, Greece. UNIPAKHELLAS Central and Toscotec’s teams at UHC paper mill in Pelasgia, Greece.

Francesco Possenti, Paper & Board Technical Manager Toscotec, says, “The successful completion of this project is a great satisfaction. Toscotec realized the new line from a greenfield, including the building layout, the civil works and the entire paper machine from the headbox to the rewinder. Throughout the project when we were faced with challenges including the pandemic, local authorizations, erection and auxiliaries, the excellent cooperation with UHC made all the difference and we managed to effectively overcome every single issue together.”

About UNIPAKHELLAS S.A.
Established in 2008, UNIPAKHELLAS S.A. is an international company and member of INDEVCO Group, a multinational corporation with diversified manufacturing, technical and consultancy services. UNIPAKHELLAS operates several facilities in Greece, including locations in Athens, Pelasgia, Thiva, Thessaloniki and Crete. It has a leading role in the paper and packaging market with a strong belief in the need to develop innovative, eco-friendly solutions. 

Contact
Enrico Fazio
Sales Director, Paper & Board division Toscotec
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Mirae Paper started up a TT SYD Steel Yankee Dryer supplied by Toscotec to replace an existing cast iron Yankee on PM2 at their Jeonju mill in South Korea. This is Mirae Paper’s second TT SYD installation following another Yankee replacement by Toscotec on PM3 in 2013. 

Market leadership through continuous development
2023 07 18 101054With over 260 TT SYD sold worldwide, Toscotec is the undisputed market leader of Steel Yankee Dryers in the global tissue market. This leadership gives Toscotec a vast experience of monitoring and servicing steel Yankees that operate in the most diverse conditions across 5 continents worldwide. This combined expertise propels the strides that Toscotec continuously makes in product improvement developments.

The latest generation of TT SYD installed on Mirae Paper’s PM2 benefits from an ideal ratio of the height, width, and distance between the Yankee’s internal ribs and the optimization of its shell thickness. This design guarantees the highest possible thermal energy transfer efficiency at the drying heart of the tissue machine.

Following the global success of its Steel Yankees, in 2016 Toscotec set up its TT SYD Technology Center in Massa (Italy), an integrated facility fully dedicated to their manufacturing with a short and easy route to a seaport to accelerate shipping anywhere in the world.

Yeong Rok Lee, Mirae Paper’s Production Manager, says, “We are very happy with the outcome of this second Yankee replacement by Toscotec. This new Yankee on PM2 has been performing very efficiently for over 2 months now. Just like our first TT SYD on PM3 has done for more than 10 years now, with great reliability and substantial energy savings.”

Simone Pieruccini, Pressure Vessel Technical Manager at Toscotec, says, “Toscotec has without a doubt the longest and largest experience in the design, manufacture, and service of steel Yankees in the tissue industry. This allows us to continuously raise the bar in terms of technological progress and service quality. We are happy that Mirae Paper can benefit from this experience on both PM2 and PM3, increasing capacity while reducing operational costs.” 

About Mirae Paper Co., Ltd.
Established in 2000, Mirae Paper operates one paper mill in Jeonju, South Korea. The company manufactures up to 65,000 tpy of high quality tissue, including toilet tissue, handkerchiefs, and towels, using both virgin and recycled fibres. It distributes its products mainly to the Korean market. 

Contact
Fabio Bargiacchi
Sales Manager, Tissue division Toscotec
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Italian specialty paper manufacturer Cartiere di Guarcino has started up PM2 at its Guarcino paper mill after a successful rebuild of the forming and press sections supplied by Toscotec. PM2 produces high-quality decor specialty papers.

Targets achieved 
The rebuild achieved its dual target of paper quality improvement and production increase. Firstly, the project ensured improved fiber distribution in Cross Direction (CD) by guaranteeing the efficient operation of the shaking system. As a result, Toscotec delivered enhanced formation and paper quality. Secondly, the press section rebuild increased post-press dryness, leading to a production capacity increase. 

A fully customized rebuild 
Based on the analysis of PM2’s operating conditions, Toscotec delivered a fully customized design solution applying both Toscotec’s and Voith’s technology in the forming and press sections. 
In the forming section, Toscotec installed a customized breast roll and Voith’s FloatBearings to enhance paper formation by boosting the performance of an existing shaking unit. It installed Voith’s EdgeMasters on the forming wire to deliver optimal paper web edge, as well as successfully operationalized a new wire stretcher and tail cutting unit. 
In the press section, the rebuild consisted in the installation of a new second nip with associated felt run, the overhauling of the hydraulic system, and a customized technological doctoring system equipped with savealls to improve water removal. 

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Simone Principia, Plant Manager of Cartiere di Guarcino, says: “Thanks to the good teamwork between Toscotec, Voith and CDG technicians, the start-up went very smoothly, and we continue to see performance improvements even beyond our expectations. The fully tailor-made technological solutions provided by Toscotec have increased PM2’s production and set a higher standard of quality, which is key for our customers.” 

Enrico Fazio, Sales Director of Toscotec’s Paper & Board division, says: “The synergy with Voith was very successful on this rebuild, where we implemented the best tailor-made solution for Cartiere di Guarcino. In the high-end segment of decor papers, they are now fully equipped to meet the market’s demanding requirements, thanks to their solid papermaking capability.” 

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 will supply two TT SYD MG Steel Yankee Dryers for Machine Glazed paper to the Indian paper manufacturer Chandpur Enterprises Ltd. at their paper manufacturing facility near New Delhi in Uttar Pradesh. The MG dryers will replace the two local steel cylinders installed on their PM1 and PM2 that produce MG Paper in the basis weight range from 40 to 70 gsm. The start-up of the two dryers is scheduled for mid-2024. 

TT SYD MG: Toscotec’s Steel Yankee expertise for MG application 
Especially designed for MG application, TT SYD MG dryers tap into Toscotec’s 20+ year experience in the design and manufacturing of Steel Yankee Dryers. This expertise ensures the highest paper quality with optimal smoothness and an increase in the drying performances of MG machines. After the rebuild, the reliability and thermal energy efficiency of TT SYD MG will substantially boost the performance of the complete production lines. 

A big leap in production capacity and paper quality
The two TT SYD MG dryers are designed for a maximum steam pressure of 10 barg and have a diameter of 14ft and 16ft respectively for PM1 and PM2. In order to ensure optimal paper gloss, they will feature Voith’s Terradry metallization, designed specifically for MG application. 

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The replacements have two targets. The first is to substantially increase the machines’ production capacity overcoming the operating limits of the existing MG cylinders. The second target is to significantly improve paper quality, and moisture profile uniformity. 

Amit Mittal, Executive Managing Director at Chandpur Enterprises Ltd., says, “These projects are an integral part of Chandpur’s expansion strategy. We expect to achieve a strong boost in production output, in order to secure the increasing amount of orders we are receiving. Toscotec’s advanced technology will allow us to be well equipped to reap the benefits of the current positive growth trend of MG Papers in India”.

Giancarlo Gianlorenzi, Sales Manager at Toscotec, says, “I’d like to thank Chandpur Enterprises Ltd. for their trust in Toscotec’s advanced technology in a market with strong price competition. Based on the positive results of our TT SYD MG’s references, we are confident that they will achieve the competitive advantage and reliability they seek in the MG paper market.”

About Chandpur Enterprises Ltd.
Founded in 1998, Chandpur Enterprises Ltd. manufactures different grades MG Paper at their production base in Chandpur, Uttar Pradesh, India. The company produces approximately 3,000 tons per month for the domestic and Asian markets. 

Contact
Giancarlo Gianlorenzi
Sales Manager, Paper & Board division Toscotec
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Fabio Bargiacchi
Sales Manager, Tissue division Toscotec
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Toscotec has been certified to the International Organization for Standardization (ISO) 45001:2018 occupational health and safety management system. The certification was issued by Certiquality, an independent third-party assurance body validated by Italy’s national accrediting agency Accredia. 

Health and safety culture is considered of paramount importance at Toscotec. This new certification is part of a broader effort to prioritise safety through education, training, and awareness-raising activities at all its locations, and it confirms Toscotec’s strong focus on identifying, addressing, and reducing potential risks. The ISO 45001 certification complements the company’s long-standing ISO 14001:2015 and EMAS certifications.

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Andrea Marzaro, Operations Director (COO) at Toscotec, says, “Achieving and maintaining ISO certifications is part of Toscotec’s corporate sustainability strategy. The ISO 45001 keeps us on the right track to monitor, manage, and deliver continuous improvement on our Occupational Health and Safety system. Along with our long-time environmental certifications, day by day we put in place a valuable, reliable, and effective HSE (Health, Safety, Environment) management system and team.”

About Toscotec
Founded in 1948, Toscotec specializes in the design and manufacture of turn-key projects, complete machines, rebuilds and stand-alone systems for the tissue and paper and board industries. Headquartered in Lucca, Italy, with subsidiaries and service centers in China and North America, Toscotec offers cutting-edge technology and customized solutions to paper producers around the world. Energy efficiency, energy saving, and quality are the basis for all its research and development, design, and manufacturing. From 30th April 2020, Toscotec is part of the Voith Group.

Contact
Andrea Marzaro
Operations Director (COO), Toscotec
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Saudi Paper Group (SPG) has started up a Toscotec-supplied AHEAD 2.2 tissue machine and OPTIMA slitter rewinder at its Dammam mill in Saudi Arabia. The new machine (PM2) is already producing high quality tissue.

The AHEAD 2.2 line has a sheet trim width of 2,850 mm, a maximum operating speed of 2,100 m/min, and an annual production capacity of over 30,000 tons. Equipped with Toscotec’s upgraded shoe press design TT NextPress, a third-generation TT SYD Steel Yankee Dryer with patented deckle head insulation, and high efficiency TT Hood, the tissue machine ensures optimal energy efficiency. Toscotec also supplied the stock preparation system and its patented Short Approach Flow with double dilution, which guarantees a further reduction of electrical consumption.  

In 2022, SPG placed a new order with Toscotec for the full-on turnkey supply of a new tissue line, including an AHEAD 2.2L machine (PM5) and two OPTIMA 2600L slitter rewinders. The project is slated to add 65,000 tons to the group’s annual capacity in 2024. 

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Mohamed Abdelghaffar, SPG Group Operations Director, says, “We are very pleased with this successful start-up, and with Toscotec’s ability to manage the entire project with flexibility and competence. We expect to quickly achieve excellent performances on PM2 both for tissue quality and production efficiency. SPG’s project team is already working with Toscotec on the engineering phase of PM5, our new, double-width AHEAD tissue line. We are happy to continue this partnership, taking together another important step in our growth strategy.”

Andrea Paganucci, Toscotec Project Manager, says, “The good cooperation between SPG and Toscotec throughout the entire project could only result in a successful outcome. Considering that Toscotec’s new line replaced an older machine in an existing building, we’ve faced a few challenges linked to space restraints of the plant layout. This is when Toscotec’s well-known flexibility can really shine bright: the customized design we delivered has effectively resolved all these issues. We look forward to continuing this close partnership on SPG’s second Toscotec machine.”

About Saudi Paper Group 
Headquartered in Dammam (Saudi Arabia), Saudi Paper Group is the leading tissue paper manufacturing company in the GCC (Gulf Cooperation Council) and MENA (Middle East and North Africa) regions. Established in 1989, SPG has been listed on the Saudi Stock Exchange (Tadawul) since 2006. Saudi Paper Group combines the efficiency of a large organization as it has earned the expertise of orchestrating a phenomenal paper empire. The group integrates 3 lines of business: Paper Recycling (SRC), Tissue Jumbo Rolls manufacturing (SPM) and Tissue Converting (SPC) businesses. With expanded operations both domestically and internationally (Kuwait, UAE, Turkey, Algeria, and Morocco), it specializes in the manufacturing of high quality, hygienic and environmentally friendly tissue products in compliance with local and international requirements.

Contact
Fabio Bargiacchi 
Sales Manager, Tissue division Toscotec
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Norwegian manufacturer Ranheim Paper & Board selected Toscotec for the dryer section rebuild of PM5 at its paper mill in Ranheim, near Trondheim. Scheduled for the third quarter of 2023, the project will increase the paper machine’s production capacity and efficiency. PM5 produces cardboard and solid board in the basis weight range from 220 to 540 gsm. 

The rebuild of PM5’s entire dryer section will consist of different phases. The first phase will see Toscotec supply new felt runs including stretcher and guide systems suitable for higher felt tensions, as well as some internal felt loops to deliver improved cleanliness. The target of this phase is to enhance the overall dryer section production efficiency by increasing felt tensions. The associated services include complete erection with supervision, commissioning, and start-up assistance. 

Øistein Vedahl, Managing Director at Ranheim Paper & Board, says, “This rebuild represents a strategic investment aimed to increase the production and efficiency of PM5. We selected Toscotec because we knew their ability to successfully manage rebuild projects, and we were impressed with their technical solution during the discussion of the project.”

Norwegian manufacturer Ranheim Paper & BoardNorwegian manufacturer Ranheim Paper & Board

Giancarlo Gianlorenzi, Sales Manager at Toscotec, says, “With this rebuilding project, Toscotec sets foot in a highly technological market. We are pleased to begin a cooperation with Ranheim Paper & Board in Northern Europe. Toscotec’s ability to provide dryer section rebuilds that include customized engineering, project management, erection, and start-up all in one package has an interesting potential in this market area.”

About Ranheim Paper & Board
Founded in 1884, Ranheim Paper & Board has a long history as an innovative papermill and one of the world’s most northerly papermills. Following the restructuring of Peterson Packaging group in 2016, the company was named Ranheim Paper & Board, which is owned today by Fundermax. It currently has 215 employees and a production capacity of approximately 120,000 tpy of paper and 50 million m2 of solid board. 

Contact
Giancarlo Gianlorenzi
Sales Manager, Paper & Board division Toscotec
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