Displaying items by tag: acelli group

Big data has been a buzzword for a few years now, as computer capabilities increase and data acquisition grows.

In the manufacturing sector, industries are seeing massive increases in the amount of data coming from their production lines, thanks to Industry 4.0 technology that makes use of machines embedded with sensors and wirelessly connected to the cloud for machine-to-machine (M2M) and Internet of Things (IoT) communication.

However, along with these massive amounts of data comes the need to effectively manage them, and this links directly to the concept of data as an asset.

2020 01 28 140846Data as an Asset explained

A data point is only a number which, considered in isolation, may have no value, and the same reasoning can also be extended to an entire data set. The concept of Data as an asset that implies that data acquire value when put in relation to other data and to business operations. In other words, these data, when analyzed together, increase their total value by helping inform business and factory decisions and strategy more effectively than they could do if considered by themselves

Read more: How to set up data driven production processes in tissue & nonwovens industries

How to manage Data as an Asset

Traditionally, a tissue and nonwovens company collected data that would provide a view into the productivity and profitability of a production line. This might be data such as costs, the production volume and the demand for the product.

Now, thanks to the Industry 4.0, the companies are provided with detailed machine data (speed and tension) and environmental data (temperature and humidity).

  • The first step in managing data as an asset is to combine the traditional data with the operational ones to come up with a complete picture of the operations and the productivity.
  • The next step is to ensure that all data is accessible via a machine-and software-independent platform. This platform must provide features such as artificial intelligence (AI) and machine learning to analyze the data and recognize patterns, thanks to which the companies can enjoy fully automated adjustments to the production processes and predictive maintenance scheduling.
  • Finally, these data must be accessible to and well-managed by everyone at the company. It should be everyone’s responsibility to ensure these data are used to balance corporate operations for maximum profitability. This allows every worker at the company, from the top down, to optimize the data for their needs, while still recognizing the needs of the company as a whole.

Read more: How to manage data governance in an Industry 4.0 system

Using Data as an Asset for intelligent collaboration

With Industry 4.0 technologies and proper management of data as an asset, tissue and nonwovens companies can ensure intelligent collaboration between the production line and the converting line. Each machine on these two lines, as we previously said, will be outfitted with sensors capable of transmitting operational data in real-time, and all of these data will flow to a single platform where they can be integrated and analyzed by AI.

The advantage of this setup is that the AI will be able to detect anomalies and small changes in the operation of any single machine or one of its part that might disrupt the flow of production and converting.

An example might be when the master roll rewinder is not moving at a speed fast enough to accommodate the rolls coming off the production line. The data will reflect this inconsistency and the speed of either the toilet roll rewinder or the production line will be adjusted automatically by the AI program.

Another example could be when there is a faulty part in the paper log cutter, resulting in the need to take the converting line offline. The data analysis will result in the automatic redirection of the roll coming off the production line to a functioning converting line.

Read more: How to measure tissue and nonwovens mill machinery performance with real time analytics

A.Celli Digital Solutions for Data as strategic Asset

A.Celli Digital Solutions has been designed to fully and automatically manage data as an asset. This cloud-based platform provides:

  • a distributed real time monitoring system called “Machine Monitoring”;
  • a business intelligence platform called “Efficiency 4.0”;
  • a Product Passport methodology called “iREEL”. 

iREEL is particularly important when it comes to intelligent collaboration between the production and converting lines, because it provides a fully integrated framework that enables communication between the data that comes from the different machines on each line and the data coming from industrial and business applications.

Data is no longer something companies can afford to collect and store somewhere they will gather virtual dust, but they must be viewed as an asset that can be used to positively impact production and corporate operations. In the tissue and nonwovens industry, data as an asset is a critical component in ensuring the smooth flow of product from the production line to the converting line and the optimal efficiency of the production process.

For more information about one of the best Industry 4.0 solution that can boost productivity on your tissue and nonwovens production line, download our free eBook "A.Celli Digital Solution: Your Fellow Traveller on Your Journey Through Industry 4.0"!

Published in European News

In today’s world consumers want to know if the companies they do business with are acting in a sustainable manner. In addition, the environment is teetering dangerously close to the point of no return when it comes to carbon emissions, and manufacturers are increasingly expected to reduce waste and energy usage, while making the highest quality products possible.

This is a tall order, but it is one that every company within the manufacturing sector must meet, including the tissue and nonwovens ones.

One of the issues that has to be addressed to achieve our objective is the loss of productivity on a production line, and one of the top reasons for this is machine idle times.

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What is Idle Time

Idle times occur when a machine is unproductive for reasons that are outside of the control of workers or management. During this idle time, workers are generally waiting while a machine is being serviced or it is offline, and the production can continue only if the idle machine can be bypassed.

Impact of machine Idle Times

When machinery on the production line is idle, the cost for a factory is between 5% and 20% of its productivity capacity. Not only that but an estimated 80% of industrial facilities are not able to accurately estimate the scope of their machine idle times.

It is common for facilities to underestimate the cost of these machine idle times by as much as 200% to 300%, and when it comes to meeting production targets and profit margins this is unacceptable. The starting point for a tissue and nonwovens plant is to gain an understanding of their machinery and what causes idle times to occur.

Causes of Idle Times

Idle times can be either planned or unplanned. The former are generally for regular machine maintenance, software and hardware upgrades, inspections, and anything else required for the upkeep of the machine, while the latter are are generally due to machine breakage or malfunction, software or hardware errors, or overall poor performance. It goes without saying that unplanned idle times are costly and obviously more disruptive because they can cause significant interruption to productivity. 

According to the American Productivity and Quality Center (APQC) unplanned idle times are responsible for a loss of between $0.40 and $1.20 for every $20, and it is therefore vitally important for every manufacturing company to avoid these phenomena.

Reducing and Optimizing Machine Idle Times: 4 key tools

The Industry 4.0 technology is the answer to these problems.

Industry 4.0 has brought machine communication and automation to a point at which data can be collected from every machine of the production line in real-time and subsequently analyze these data in isolation or in relation to those coming from every other machine.

Read more: How to measure tissue and nonwovens mill machinery performance with real time analytics

To accomplish this, there are a number of tools that tissue and nonwovens companies need to have in place.

1. Machine Sensors

Each machine on the production line will be equipped with numerous sensors in order to collect data in real-time during operation. These data will reveal, for example, the operating state of the machine, its speed, vibrations and other environmental factors, such as temperature and humidity, that the human senses cannot detect.

2. The Cloud

Thanks to Cloud computing, the various machines will be connected wirelessly to each other, as well as to computers and mobile devices used by workers on the production line and in head office. This will allow for the remote collection and analysis of data from any production line in any plant.

Read more: Cloud Computing and Integration with Machine and Corporate Applications

3. Software/Platform

The data that are sent across the cloud will need to be integrated into a single platform capable of analysing them and to allow both a bird’s eye view of the production line and a closeup view of the operation of any individual machine.

This data integration is incredibly important in light of the fact that the machines on production lines tend to have their own unique software, isolating their data from those of the other machines and from every other data related to business operations. 

4. AI/Machine Learning

Finally, artificial intelligence and machine learning will be capable of analyzing the data coming in, recognize anomalous ones and act accordingly. Machine learning will use algorithms to understand anomalous readings and to schedule predictive maintenance. These tools are key in improving machine performance and reducing unplanned idle times or avoiding it altogether.

Reduce Idle Time and Boost Productivity with Industry 4.0

We have seen that, despite the pressures to which companies are subjected, there is nowadays a technology capable of minimizing or eliminating machine idle times.

Thanks to these tools you will be able to gather all the data sent by disparate machines in any production line, integrate them, analyze them, interpret those analyses, and implement automated measures to ensure machines are always running at peak efficiency.

For more information on how to keep your tissue and nonwovens production line operating at peak efficiency, download our free eBook “5 Industry 4.0 Tools that Boost Productivity in the Tissue Paper and Nonwovens Industry”!

Published in European News

Efficiency and quality of wrapping with the new A.Celli Pope Reel

The Italian company, part of Burgo Group, a well-known producer of graphic and special papers, based in Lugo di Vicenza, has accepted the reconstruction of the pope reel section of the multi-cylinder PM#5 machine made by A.Celli Paper.

The start-up, which took place successfully and entirely within the agreed times, and the good quality of the product supplied by A.Celli have allowed the customer to obtain excellent results for the past year with all types of special papers produced by the plant.

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Mosaico Group specifically requested A.Celli Paper to optimise the PM#5 Paper Machine by replacing the end-of-line section with a new pope reel, with center wind technology, equipped with automatic NIP, tension and torque controls and that uses HMI software to interface with the machine's DCS.

The design peculiarities, both hardware and software, and the manufacture of the new section permit optimal management at a production speed up to 900 mpm, with a width of 2830 mm, for special papers.

A.Celli’s experts are available for consultancy, for any equipment inspections and for detailed control planning, as well as for updating and improving the efficiency of pre-existing machinery and software, in order to optimize its performance in terms of productivity, safety and automation.

Published in European News

A.Celli Paper is pleased to confirm its ongoing and valuable collaboration with the Chinese group Shanying Huazhong Paper Industry Co., Ltd., enshrined in the agreement for the supply of two latest generation E-WIND® P100 rewinders, for the mill located in Zhangzhoi City, in Fujian province, China.

The E-WIND® P100 Paper Rewinders, highly developed in terms of design, will have a paper width of 6660 mm and will guarantee a maximum production speed of 2500 mpm (operating speed).

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They are combined with sophisticated technological innovations including:

  • Innovative Slittomatic® double motor cutting unit positioning system;
  • Web-in technology, the automatic system that maximises the management of positioning cutting units without the need to break the web, with considerable time and safety savings for operators;
  • Jumbo roll parking station and shuttle (mobile trolley on rail) for their handling.

These two rewinders have been selected by the Chinese group to process medium board paper, with basis weight range from 80 up to 160 gsm.

Liansheng Paper had already purchased two other rewinders, with the same width, in 2016 and Shanying Group, of which the paper mill is part, bought two large-width paper rewinders (8 meters) from A.Celli last year.

An important new confirmation of a consolidated partnership between Shanying Group and A.Celli, which underlines the success of the paper rewinders A.Celli E-WIND®.

Published in Asian News

A.Celli Paper is pleased to confirm its ongoing and valuable collaboration with the Chinese group Shanying Huazhong Paper Industry Co., Ltd., enshrined in the agreement for the supply of two latest generation E-WIND® P100 rewinders, for the mill located in Jingzhou District, China.

The E-WIND® P100 Paper Rewinders, highly developed in terms of design, will have a paper width of 7960 mm and will guarantee a maximum production speed of 2500 mpm (design speed).

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They will be able to accommodate large reels on the unwinder, with diameters up to 3800 mm and weighing about 65 t.

In addition, they are combined with sophisticated technological innovations including:

  • Web-in technology, the automatic system that maximises the management of positioning cutting units without the need to break the web;
  • Built-in spool-parking.

The machines, with start-up scheduled for the third quarter of 2019, will allow the Chinese group to process high-quality flat-paper and test-liner paper of the lowest grammage (from 50 to 110 gsm).

This new investment by Shanying Huazhong Paper Industry is further confirmation of how technologically reliable and evolved Paper A.Celli E-WIND® Rewinders can prove to be, and now A.Celli Paper is considered a valuable and expert partner, able to constantly support its customers, building and cultivating important professional relationships.

Published in Asian News

A.Celli Paper is pleased to begin a valuable collaboration with the French company for the supply of a complete tissue production plant.

Global Hygiène has chosen to rely on A.Celli Paper technology for the order of a complete turnkey plant to be installed in Charavines, in southeastern France.
The French company has secured the A.Celli technological excellence, from the stock preparation to the roll handling system.

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The new iDEAL®1800S machine will have a 2850 mm format and an operating speed of 1800 mpm. The project also includes an E-WIND® T100 rewinder and a R-WAY® roll-handling system.
The Yankee supplied is the forged one of the latest A.Celli generation and has a diameter of 15’.

Luc Brami, CEO of Global Hygiène, said that the production of Charavines, estimated in 30.000 t/y, will cover the needs of the two Global Hygiène group’s converting plants, in Auxonne and Vern d’Anjou, consolidating the company’s leadership position in the market for hygienic products.

As usual A.Celli has given its total availability in experience and professionalism to the customer, with a full spirit of partnership.

The delivery is expected for the fourth quarter of 2019.

Published in European News

The important rebuilding operation was successfully completed by A.Celli Paper and ended with the start-up of the Israeli customer's machine

In early October, the Customer Service team at A.Celli Paper launched the Tissue Machine TM1 of Shaniv Paper Industries Ltd, the second largest Israeli paper manufacturer for home use.

The operation consisted in the supply of a new reel, an innovative DCS system, a set of more efficient motors, renewed roller equipment and the relative drives. The dryer roller (Yankee Dryer) was also insulated by shielding the heads with a layer of coating.

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The operation, completed by a team of qualified technicians, allowed the machine to reach the speed of 1500 mpm for the production of high quality tissue paper.

The ambitious project was carried out in full compliance with the client's expectations, which complimented the team of A.Celli Paper for the excellent work performed.

The technicians will also accompany the customer's operators during this first post-start phase, for a brief period of baby sitting based on the well-known spirit of partnership that has always distinguished the A.Celli Group.

Published in European News
Thursday, 11 October 2018 18:26

A.Celli E-WIND® T80S: flexibility close at hand

A.Celli Paper presents a new rewinder of high production flexibility.

The two goals were to optimise production and increase line productivity.

Both have now been achieved, limiting investment to a minimum, with E-WIND® T80S: the new rewinder designed by A. Celli Paper to respond to these very needs.

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A.Celli Paper E-WIND® T80S is a modular and fully automatic entry level rewinder, with built-in electrical cabinets, capable of managing products that involve a specific volume, diameter and cutting format while also guaranteeing extra capacity during production peaks.

It is customisable, plug-and-play, perfectly adaptable and compatible with any standard rewinding system or complete line in the tissue sector.

A.Celli Paper E-WIND® T80S: flexibility for everyone!
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Published in European News
Tuesday, 04 September 2018 09:24

A.Celli Safety Upgrade: safety first!

The best choice to manage the adaptation and compliance of industrial machinery or plants.

The A.Celli Group has always retained technological developments and the safety aspects of machines to be its key growth factors. The Group’s approach to occupational safety is a foundational theme for the company, and the high number of plants sold throughout the world in relationship with a practically inexistent history of accidents on the job is the most evident proof of this philosophy.

Today, the complexity of industrial systems requires increasingly attentive consideration of the theme of safety. Preventing accidents on the job is not a calculation based on a single machine but an outcome of the management logic adopted throughout the production process.

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And in addition to the normal risk factor, unpleasant unexpected events can arise from deficiencies at the operating phase, lack of clarity in procedures, negligence by operators or human errors. Without forgetting that year after year, international norms and directives to regulate the issue abound.

For this reason, A.Celli offers its customers the complete solution for plant modification, repair, verification and/or compliance.

The service offered includes:

  • Analyses surveys and assessment of customer demands
  • Engineering study on components sizing and on plant design with reference to binding norms in the country in question.
  • Project management, document handling and issuing of certifications.
  • Installation, commissioning and start-up
  • Software modification and updating of electrical and pneumatic diagrams.
  • Review of manuals and layout of new safety devices.
  • 24/7 technical support hotline
  • 12-month warranty from the date of completion of the modifications.

The best choice to manage the adaptation and compliance of industrial machinery or plants.
So what are you waiting for?

Contact A.Celli Customer Service (This email address is being protected from spambots. You need JavaScript enabled to view it.) for a quick consultancy or a dedicated case study.

Published in European News

A.Celli Paper celebrates with great satisfaction the start-up of three E-WIND® winders for tissue, installed in Indonesia for the customer Asia Pulp & Paper (APP).

In March, a set of new generation E-WIND® T200 winders was installed at APP’ s Perawang mill in Indonesia.

The start-up and subsequent running-in all went smoothly, with the customer’s complete satisfaction. It is one of many other successful business machinery equipment partnership through the years that A.Celli Paper is achieving with the world-wide based International Group.

The three new generation winders, being a partial delivery of a larger sizeable order currently under delivery e/o installation, consisting of two E-WIND® T200 winders, a calender and Slittomatic® automatic knives positioning system, and an additional E-WIND® T200 winder.

With this project, A.Celli Paper has offered the customer a giant leap in quality for meeting high and ambitious production targets to increase and strengthen its presence in Indonesia and through the whole Asia.

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About Asia Pulp & Paper
Asia Pulp & Paper (APP), part of Sinar Mas, is a trade name for a group of pulp and paper manufacturing companies in Indonesia and China. APP is responsible for delivering quality products to meet the growing global demand for tissue, packaging and paper, with an annual combined pulp, paper, packaging product and converting capacity of over 19 million tons per annum. On any given day, APP’s products find their way into the hands of consumers in various branded forms from all over the world.

Ensuring supply chain integrity and commitment to the Sustainable Roadmap Vision 2020 are crucial to APP’s operations.

Learn more about APP’s path to operational excellence by reading our Sustainability Reports and Forest Conservation Policy at www.asiapulppaper.com

Published in Asian News
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