The scope of supply also includes erection supervision, commissioning and start-up assistance, as well as onsite training programs on operation and maintenance.
With this new double reference, Toscotec enters the growing Philippine market and strengthens its undiscussed leadership as global manufacturer of steel Yankee dryers. In Asia alone, Toscotec has sold over one hundred TT SYD, out of more than 200 units worldwide. Particularly in the segment of replacing cast iron Yankee with steel Yankee dryers, Toscotec is very far ahead of the game, with over 80 TT SYD replacements in five continents around the world.
Mr. Emmanuel Gaspar, Executive Vice President of Bataan 2020, Inc. declared, “At Bataan 2020, we are committed to responsible industrial production to protect the environment. Among other projects, we produce steam from renewable power sources. Toscotec’s TT SYD make it possible for us to actually reduce steam consumption and keep up the highest standard of efficiency on our operations. We are happy to say that the two TT SYD have been performing extremely well since start-up”.
Gabriele Martinelli, Toscotec’s Area Sales Manager Asia & Pacific replied, “We are very proud to see Toscotec’s cutting edge technology applied to a green project, such as Bataan 2020’s. The market is definitely moving toward the most efficient drying solutions, which deliver the best performances with the lowest ecological footprint. This is why we are confident that TT SYD and its continuous evolutions will play an increasingly important role in the years to come”.
About Bataan 2020, Inc.
Bataan 2020 is one of the leading manufacturers of fine quality paper, board and tissue in the Philippines. It operates paper mills in Samal, Bataan and Baesa, Quezon City to produce over 100,000 metric tons of paper annually. With roots in the paper industry dating back to 1956, Bataan 2020 has built on its papermaking experience and has grown to include businesses in renewable power generation and chemical manufacturing.
The second generation TT SYD-16FT replaced a cast iron Yankee and it was started up on schedule in mid-January 2018. The scope of supply also included the complete Yankee steam and condensate system.
Toscotec is the inventor and the undiscussed market leader of steel Yankee dryers worldwide, supplying SYDs both for new tissue machines and in replacement of cast iron Yankees. This proves that paper mills across the globe acknowledge that TT SYD is the best technology currently available on the market in terms of energy efficiency, reliability and safety.
Mr. Di Leva, CEO of Paperdi, said, “After monitoring the new TT SYD for a few months, we can say that it has been performing extremely well in terms of drying efficiency and allowed us to reach the top speed. We are particularly happy with the steam consumption figures, and we expect to bear the fruits of this replacement in the long run, by significantly cutting production costs”.
About Cartiera di Pietramelara
Located in the province of Caserta, Cartiera di Pietramelara mill belongs to the Italian tissue producer Paperdi srl. Since 1989, the mill has been producing tissue products such as industrial rolls, kitchen rolls, toilet jumbo rolls and towel tissue, with the household brand “Soavex” and the professional brand “paperdi”. The current annual production is 45,000 tonnes. Inspired by a strong ecological mission, Paperdi mainly utilizes recycled materials to reduce the environmental impact of the manufacturing process.
Since its inauguration in 2016, this fully integrated plant has been operating at full capacity, implementing the entire production cycle of Toscotec’s TT SYD, from metalworking, precision mechanical machining to thermal treatment and surface metallization, up to non-destructive tests and certifications.
The sixteen TT SYD that are presently under construction feature different sizes, with diameters ranging from 3,650 mm to 6,705 mm and width from 3,100 to 6,050 mm. Toscotec has been manufacturing the world’s largest diameter steel Yankee dryers and their demand has been steadily going up to this day: 50% of the TT SYD currently under construction have diameters from 18 to 22 ft. In view of this, the strategic choice of the Technology Lab’s location offers a clear logistical advantage, by ensuring that large diameter Yankees get easy access to the seaport for expedite shipping operations.
The market’s demand for medium and large diameter TT SYD is far-reaching around the globe. The orders for these sixteen Yankee cylinders come from paper mills situated across four continents: Asia, North and South America, Europe and Africa, with Asia and the Americas together taking the lion’s share.
Toscotec sustained operations in the manufacturing of TT SYD are testament to the success of Toscotec’s design, including large diameter Yankees. Feedback from the first installations of 18 ft Yankees and of 22 ft Yankees have been of substantial improvements in drying efficiency, attracting paper mills to the opportunity of cost savings. Toscotec’s global market share of steel Yankee dryers exceeds 60% and nearly all new steel Yankees currently installed in paper mills in Western Europe are Toscotec-supplied.
Parallel to the success of its manufacturing operations, Toscotec is relentlessly striving for new breakthroughs with its R&D division. Following the engineering of the second generation TT SYD in late 2013, with improved rib design and metallization, as well as increased thermal exchange, Toscotec’s steel Yankee dryers are now looking into the future with their third generation’s design, which will be presented later this year.
PM5 project is a turnkey supply by Toscotec, which includes the stock preparation system, the AHEAD-2.0S tissue line, the electrification and control systems, the complete plant engineering, erection, and supervision for erection, commissioning, training and start-up.
The scope of supply also includes the dust and mist removal systems and the hall heating and ventilation systems. Overall, the plant benefits largely from the numerous stages of energy recovery of the gas-fired hoods and vacuum plant.
Toscotec’s AHEAD-2.0S tissue machine is equipped with a second-generation TT SYD-15FT steel Yankee dryer of 15 ft diameter. It features Toscotec’s advanced shoe press technology TT NextPress. The AHEAD-2.0S is set to produce premium-quality super-soft toilet tissue, with a total production of over 30,000 t/y and it will deliver on Twinsaver’s plans to increase supply to the local and export markets and preserve its top position in the tissue industry.
Following the announcement of a R580 million (USD 42 million) investment earlier last year, the Twinsaver Group - the leading producer of branded tissue in South Africa - awarded this turnkey project to Toscotec, who presented the most compelling green solutions, in line with the Group’s high environmental standards.
“We are very proud of the results of this turnkey project in South Africa. As Toscotec’s first turnkey in the country, building on the experience of other tissue machines in South Africa, we completed the supply according to schedule and started producing high quality tissue on the day of start-up. The substantial energy recovery advantages granted by the overall design of this plant are bound to exceed expectations,” said Toscotec’s Sales Director, Mr. Marco Dalle Piagge.
Twinsaver Group is the largest South African manufacturer, marketer and distributor of branded tissue products. The product range includes toilet tissue, facial tissues, roller towels, house and leisure and away from home products. Twinsaver Group head-office is located in Bryanston, South Africa, with manufacturing and converting facilities in Kliprivier, Pretoria, and Cape Town.
Toscotec’s steel Yankee dryer TT SYD-18FT was successfully fired up at Fujian Jinmin Reconstituted Tobacco Development Co., Ltd., a subsidiary of China National Tobacco Corporation, at its Luoyuan mill, Fujian, China. The TT SYD reached top performance immediately after start-up at the end of March.
The advantages of TT SYD can benefit all grades and types of paper, not least reconstituted tobacco paper. After Toscotec’s successful reconstituted tobacco application in the U.S., the Chinese reconstituted tobacco paper producer Fujian Jinmin is now operating a big diameter TT SYD, which guarantees top drying efficiency at the lowest possible consumption cost.
From the delivery of the first TT SYD in 2000 throughout 18 years of successful and safe applications and two generations of design, this achievement further reinforces Toscotec’s position as the number one supplier of steel Yankee dryers worldwide. The number of TT SYD sold in five continents around the globe has recently reached more than 200 units, way ahead of the competition. Based on its ever-growing experience, Toscotec has constantly been upgrading its design and it is currently in the process of honing the third generation of TT SYD.
Toscotec’s new Prodergy tissue machine fires up at APP Group’s Perawang mill, in Indonesia. This start-up is part of a major APP order of Toscotec’s Prodergy machines, to be installed at APP Indonesian paper mills.
PRODERGY is Toscotec’s leading innovation: an AHEAD-2.0L tissue machine, 5.6 m width, 2,000 m/min operating speed, featuring a second generation TT SYD-22FT and steam-heated hoods. Toscotec’s 22 ft diameter steel Yankee dryer constitutes a world record: the biggest steel Yankee dryer ever manufactured worldwide for tissue application. This breakthrough equips Toscotec with a significant advantage in terms of technological innovation. Prodergy’s unprecedented drying efficiency is threefold, combining the benefits of the largest diameter TT SYD ever delivered worldwide, an efficient press configuration and steam-heated Yankee hoods. Each element of Prodergy’s drying equation contributes to the best possible energy efficiency of the tissue making process. The exclusive use of steam energy throughout the entire drying process ensures significant cost reduction compared with gas energy drying. The design of the TT SYD 22ft and the steam-heated Yankee hood system with multiple energy recovery stages deliver the highest dryness rate with minimum consumptions. The press configuration guarantees the highest possible degree of mechanical dewatering before entering the energy-based drying section of the AHEAD-2.0L.
Toscotec’s Sales Director Marco Dalle Piagge affirmed, “We are extremely proud of this incredible achievement. The first 22 ft TT SYD ever manufactured and delivered worldwide, and installed on a top performance tissue making line. We are making history and we expect Prodergy to set a new record for energy efficiency in tissue”.
Vinda International Group purchased four new Toscotec AHEAD-2.0M tissue machines, to be installed in its new production base in Xiaonan district, Xiaogan, Hubei. Toscotec will deliver the first two lines in mid-March and the second two in mid-May 2018.
PM1, PM2, PM3 and PM4 will have similar configurations, including second generation large diameter TT SYD and Toscotec’s most recent technological developments in dryness efficiency, taking its widely acknowledged energy saving results to the next level.
The four AHEAD-2.0M are scheduled to come online by the end of 2018, leading to a total production increase of over 120,000 t/y for Vinda. This year the Italian supplier is also delivering two AHEAD-2.0M tissue machines to Vinda’s new Yangjiang mill in Guangdong. Overall, these six Toscotec-supplied lines will add a total of over 180,000 tons to Vinda International’s annual production output.
Toscotec Chief Executive Officer Mr. Alessandro Mennucci stated, “We know that this large project at the heart of China’s central region is of strategic importance to Vinda, and we are proud to be part of it. Toscotec will be there with today’s best available tissue technology, including our latest advancements. I am confident that Vinda will appreciate the benefits of the AHEAD-2.0M in terms of both tissue quality and consumptions.”
Located in the high-demand central China tissue market region, Vinda’s new Hubei mill will become another important strategic production base for Vinda Group.
The leading Chinese producer of hygiene and sanitary products has successfully started up the second of two Toscotec-supplied tissue machines installed at its Changji mill.
Hengan and Toscotec sealed their partnership at the end of a project that started one year ago with the order of two tissue machines, PM25 (started up in November 2017) and PM26, producing a total increase of 50,000 tons per year to Hengan’s production.
Both tissue machines have a production speed of 1,600 m/min and a width of 2.8 m. They are equipped with single layer headbox, one large diameter TT SuctionPressRoll, second generation TT SYD with improved rib design, TT Milltech natural gas high efficiency hood and steam and condensate removal system. The scope of supply also includes DCS/MCS, as well as erection supervision, start up assistance and training programs.
Hengan project team stated: “We are excited to start this new project. Toscotec-supplied tissue machines have all the technology we need to produce high quality tissue and to reduce the operating cost of our mill. We want to thank all those who contributed to the success of this partnership project.”
Marco Dalle Piagge, Toscotec Sales Director: “Now the two machines are running at their target operating speed and they are already producing marketable tissue. In spite of the environmental hardship of Xinjiang Autonomous Region in which the mill is located, everything goes fine and thanks to the good cooperation between our service team and the mill’s personnel, we achieved both start-ups in a very short time. It’s another success to add to our professional experience.”
Toscotec is confirmed as global supplier of Steel Yankee Dryers, with installations across five continents.
Encore tissue started up a new Toscotec Steel Yankee Dryer on ET3 at its Laverton North mill, Melbourne, Australia. The rebuilt tissue machine started producing high quality tissue paper immediately after start-up. The Australian tissue maker purchased a second generation TT SYD of 3600 mm diameter, to replace an existing cast iron Yankee.
Following the installation of Toscotec’s steel Yankee dryer, Encore Tissue expects to increase the machine operating speed from 1,400 mpm to 1,900 mpm. They also expect an increase in production and machine efficiency, and a real improvement of the finished product quality, from the point of view of homogeneity of the tissue structure.
With this sale, Toscotec sets a new important record in the steel Yankee dryer market: 203 TT SYD sold in 36 countries across five continents.
Marco Dalle Piagge, Toscotec Sales Director, stated: “In the year 2000 we installed the first steel Yankee dryer in Italy. Eighteen years on, we have TT SYD running in mills all over the world. We are proud of the technological revolution we have pioneered and of the journey - certainly not without obstacles – that led our company to an unquestioned leadership in the tissue market.”
Stefano Marenco, Toscotec R&D Director, stated: “What we have achieved is an important recognition, but it will not be the end of the road. Toscotec is always looking for solutions that can improve the tissue process and reduce the energy cost. TT SYD is not an exception. Our R&D department is abuzz and there will be new developments soon.”
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In 2016 Smurfit Kappa awarded Toscotec with the rebuilding of the Company´s Barbosa paper machine’s dryer section. The target operating speed of the machine after startup was set at 1,000 mpm.
Following an extensive project that lasted 25 months, with 36 days of setup from paper to paper, the PM was successfully commissioned and started up in July 2017.
The main target of the project was to improve the efficiency of the PM, by increasing its operating speed and production. The alliance between Toscotec and Smurfit Kappa has lead the packaging company to increase containerboard production to 120,000 tonnes per year which means an increase in the corrugating machines production.
Enrico Fazio, Toscotec’s Paper & Board Sales Manager stated, “Toscotec’s long-standing experience in dryer section rebuilds, using TT SteelDryer, our unique dryers with an extremely high drying capacity, and the advanced rope-less tail threading system, was the deciding factor in the customer’s choice. We are very proud of our partnership with Smurfit Kappa and we would like to thank the SK team in Barbosa for their great cooperation during the entire project”.
According to Carlos Mario Londoño, the project manager, "This was a very complex project to carry out. Thanks to the collaboration of suppliers such as Toscotec, we achieved the our goal within the time we had established”.