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Displaying items by tag: Toscotec

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.

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Europap Tezol Kağit will boost capacity with a Toscotec-supplied AHEAD 2.2S tissue machine at its integrated production base in Mersin, Turkey. This is a repeat order for Toscotec who already supplied a TT SYD steel Yankee dryer installed on their PM1 in 2012. The new line is scheduled for start-up in mid-2022. 

The AHEAD 2.2S machine has a sheet trim width of 2,920 mm, a maximum operating speed of 2,100 mpm, and an annual production capacity of over 40,000 tons. It is equipped with TT NextPress with upgraded design, third-generation TT SYD, TT Reel-BulkyReel for optimal preservation of bulk and softness, and high efficiency TT Hood with automatic balancing system. 

The supply features the complete stock preparation system and Toscotec’s patented TT SAF® (Short Approach Flow) equipped with a double dilution system to ensure electrical consumption reduction. The scope also includes Toscotec’s proprietary DCS system, electrification and controls, as well as dust and mist removal systems. Two OPTIMA slitter rewinders fitted with an automatic shaft puller complete the supply. Toscotec will provide a complete service package with detailed mill engineering, erection supervision, commissioning, training, and start-up assistance.  

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Ersin Tezol, CEO of Europap Tezol Kağit, says, “Our production capacity expansion required the most advanced technology at a cost-attractive price. Toscotec’s technology was the best choice to meet the strict environmental requirements of our company and the high quality standards of our super-prime brands, especially for softness and hand feel.”

Matteo Giorgio Marrano, Toscotec’s sales manager, says, “This AHEAD 2.2S machine will allow Europap Tezol to achieve its target of production increase and prime quality. The configuration with TT NextPress and TT SYD of new generation and high recovery TT Hood aims to provide the highest possible level of energy efficiency on a tissue production line. Toscotec also strengthens its presence in the Turkish market, which is growing into a key market in the EMEA region.”  

About Europap Tezol Kağit San. Tic. Inc.
Established in 2004, Europap Tezol is a major manufacturer in the Turkish tissue market and it operates two tissue mills with integrated converting, in Torbali-Izmir and in Mersin-Tarsus (Turkey), with an annual production of 100,000 tons. Tezol distributes its branded products and AfH tissue, including wipes, napkin, toilet and towels, in Turkey, as well as Europe, the Middle East, Russia and Latin America. 

For further information, please contact:
Matteo Giorgio Marrano, Area Sales Manager, Tissue division, This email address is being protected from spambots. You need JavaScript enabled to view it. 

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Thursday, 19 November 2020 09:45

Toscotec to supply three tissue rebuild projects

Toscotec will deliver three tissue machine rebuilds located at different mills to a confidential global producer. 

Toscotec will rebuild the drying sections of two tissue machines, as well as the wet end and winding sections of another machine. The drying section rebuilds include the supply of two Toscotec’s third-generation-design TT SYD Steel Yankee Dryers, steam and condensate systems, and high efficiency TT Hoods, including one newly optimized combustion system. The energy efficiency given by the integration of the steel Yankee and the hoods will result in a significant reduction of the tissue machines’ thermal consumption. 
The other project requires the modification of the approach flow and fiber recovery systems and the complete rebuild of the machine’s wire and pope reel sections

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The provision of expert services, including engineering, dismantling of old equipment, erection, commissioning, start-up, and training, ensures a complete package for the rebuilds.

Since the start-up of its first TT SYD in 2000, Toscotec is the forerunner and world leading manufacturer of Steel Yankee Dryers boasting close to 230 TT SYDs sold and over 200 currently operating in five continents.

 These two new TT SYDs will replace the mills’ existing Yankee dryers. Toscotec holds the record as the manufacturer who supplied all of the SYD replacements that took place in Europe to date.

Riccardo Gennai, Toscotec Sales Manager, says: “We take pride in the continuous evolution of TT SYD. Toscotec started up the first steel Yankee dryer in the tissue industry. TT SYD’s third-generation design enhances the machine’s drying performance and energy efficiency to a degree that it really makes us stand out in the market.” 

For further information, please contact:
Riccardo Gennai, Sales Manager, Toscotec Tissue division, This email address is being protected from spambots. You need JavaScript enabled to view it.

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Wepa Group is one of the largest tissue manufacturers in Europe, with 13 sites, 21 paper machines, a production of approx. 780,000 t/year, and a positive annual growth trend. Since 2002, Toscotec and Wepa’s cooperation has been particularly strong at Wepa Marsberg-Giershagen, where Toscotec supplied a new tissue line on a turnkey basis, completely rebuilt PM 5 in two different steps and installed new hoods on other two existing machines, with the result that all tissue machines at the mill are now equipped with TT Hoods.

PM 4 and PM 7 Hood rebuilds: Consumption reduction & Speed increase

In order to evaluate the return on the investment, it is always interesting to compare the efficiency of the equipment – consumption and performance - before and after the rebuild. This comparison is particularly clear if we look at PM 4 and PM 7, where the modification involved only the hoods and the air system. After the installation of TT Hood on PM 4, the mill achieved a 12.5% reduction in gas consumption and 50mpm increase in machine speed. The results on PM 7 were similar, with a 13.3% reduction in gas consumption and 50mpm increase in speed.

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In general terms, for a tissue machine that produces 30,000 t/y with a thermal consumption of 1.3MWh/t, 10% of drying energy savings equals a cost reduction of approximately 4 €/t, i.e. 120,000 €/y. Additional savings coming from electrical load reduction and machine speed increase must also be considered.

The above figures offer a clear picture of the potential benefits coming from the use of fully updated equipment including state-of-the-art devices dedicated to:

  • Energy saving: complete heat recovery chains for steam generation, air and water heating
  • Hoods regulation: automatic balancing system
  • Pollutants control: burner management system, burner control and fine-tuning

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TT Hoods: customized technology for the highest reliability

TT Hoods are entirely custom-made, in order to meet the needs of the paper machine. At WEPA Giershagen, Toscotec calculated the best combination of the open area, hole diameter, and hole pattern to achieve top performance and efficiency.

TT Hoods are designed and manufactured at Toscotec’s headquarters in Lucca, where its engineers and workers have more than 20 years of experience in hoods and air systems. This expertise guarantees the reliability and the constant improvement of their design and performances.

The art of project management in rebuild projects

Finally, time schedule is always essential in rebuild activities. Wepa Giershagen required Toscotec to schedule every phase of the project, allocating the right resources and time, in order to guarantee an accurate paper-to-paper machine shutdown period. On Wepa Giershagen PM 7 for example, the scheduled paper-to-paper shutdown was of 360 hours. The entire work was completed and tested in only 332 hours, i.e. 28 hours ahead of schedule.

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Skjern Paper is Denmark’s only paper mill. Founded in 1965, it is situated in Skjern, West Jutland. Since 2005, the ownership majority has been held by Buur Invest A/S, a Danish privately-owned investment company. The mill’s current annual capacity is 75,000 tonnes, including a range of products - coreboard, grey and blueliner, greyboard and sheets - produced from 100% recycled fibres. Skjern Paper is strongly export-oriented, with over 90% of its production sold to packaging and paper businesses in Europe.

In the third quarter of 2019, Toscotec carried out a complete rebuild of its PM1 dryer section, delivering 19 TT SteelDryers. The scope of supply was on a turnkey basis, including dismantling operations, erection, commissioning and start-up. In this interview, Kurt Larsen, Project Engineer at Skjern Paper, shares his views on the main aspects of the rebuild and his overall evaluation.

In 2019, Skjern Paper selected Toscotec to rebuild its PM1. Why did you decide to make this investment? And why did you choose Toscotec?

The main driver for the investment was the need to increase our dryer capacity. PM1 started producing at Skjern in 1967, but it was a second-hand machine, and some of its cast iron dryers dated back to the mid-1940s, some even all the way back to 1927! In order to overcome our drying capacity limits, we decided to install steel cylinders of bigger diameter, operating at a much higher steam pressure (10 barg), new frame and drives that could reach a higher speed. Toscotec’s new dryer section can achieve 800 m/min, which is double the maximum speed we had before.

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Secondly, we chose steel dryers against cast iron, because of their higher heat transfer efficiency and better safety. In terms of safety, steel cans are definitely a much better choice.

Among the suppliers we evaluated, Toscotec proved to have the most substantial experience in the design, manufacturing, operation and maintenance of steel dryers. TT SteelDryers have an incredible number of references around the world and they are manufactured internally by Toscotec. This meant we could have one single supplier for the whole dryer section, which solves the problem of grey zones in-between different manufacturers, which would save us a lot of headaches in the end. Skjern considered this aspect a great added value.

Focusing on the rebuild itself, was the project delivered on schedule? How do you evaluate its overall management?

The project was completed on schedule. Other prospective suppliers had foreseen a much longer shutdown period, but Toscotec implemented the whole rebuild within a shutdown period of only 11 days, including dismantling the old equipment and erection of the new dryer section and hood. This timeline was key for us, because bringing the production to a complete stop makes it tough for us to be the flexible supplier we want to be.

Overall, the project management was very well executed. We had committed and competent people at our disposal, and we got all the support we needed on time.

What have you achieved with this rebuild?

First of all, we have registered a production increase of more than 11% so far, but we expect to achieve even more after removing the bottlenecks we still have in the wet-end and press section. Secondly, the rebuild lifted the speed limit we had, allowing us to increase the machine speed, particularly for lower grammages.

What can you tell us about the erection, commissioning and start-up?

The erection was very efficient. We were working 24/7 under safe conditions, without any injuries. Start-up went very smoothly, with a delay of only one day, which was not caused by Toscotec. We are very satisfied with the onsite implementation of the rebuild.

How would you describe the cooperation with Toscotec?

We had very good cooperation with Toscotec. They were attentive to our needs and committed to meet them in the best possible way. If during the erection we had an extra job for them to do or they needed something from us, we helped each other, so that the work was flowing really well. They proved to be very flexible and cooperative. For example, they lent out several people for a few days to help finish up some pipe work. They were working with us towards a shared objective and did not back out when we needed extra help. This is very important to a small mill such as ours, because we have limited resources and therefore we appreciate a supplier who is prepared to go the extra mile to get the job done.

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In June 2020, Toscotec successfully rebuilt the approach flow and wet end of PM4 at Papeterie Le Bourray in Saint-Mars-la-Brière, France. After two months of stable production, PM4 exceeded the performance targets relating to the improvement of sheet formation quality and cross direction basis weight profile. After the rebuild, the operating speed of PM4 increased by up to 10%.

The project included a new fan pump and a fully hydraulic TT Headbox. Toscotec also supplied a complete service package, comprising detailed engineering, dismantling operations, erection, commissioning, start-up supervision, and training.

Through the joint effort of Toscotec and Papeterie Le Bourray, the project pushed ahead during the Covid-19 lockdown in France and Italy, and it was executed according to schedule.

Toscotec’s TT Headbox-SLT. Toscotec’s TT Headbox-SLT.

Alexandre Pappalardo, Head of Maintenance & TN at Papeterie Le Bourray, says, “We are very satisfied with the outcome of the project. Toscotec respected the time limits of machine shutdown and the new TT Headbox delivered on the performance targets. The restrictions in place during lockdown required extra efforts from both companies, but our good cooperation made it possible to complete the rebuild on schedule.”

Andrea Paganucci, Project Manager at Toscotec, says, “Papeterie Le Bourray provided Toscotec Service team with the best possible working conditions during lockdown. We were united by a common determination to achieve the project targets and we succeeded. The new TT Headbox features a tailor-made design that allows the mill to operate in the current Tisco Former configuration but also in Crescent Former configuration in the future.”

For further information, please contact: Marco Dalle Piagge, Sales Director, Toscotec Tissue division, This email address is being protected from spambots. You need JavaScript enabled to view it. Riccardo Gennai, Sales Manager, Toscotec Tissue division, This email address is being protected from spambots. You need JavaScript enabled to view it.

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Toscotec will supply a second-generation TT SYD Steel Yankee Dryer to the Colombian tissue manufacturer Cartones Y Papeles Del Risaralda. The new TT SYD will replace a cast iron Yankee on PM1 at its Risaralda mill in Western Colombia.

Toscotec’s Steel Yankee dryer will increase PM1’s production capacity, while reducing its overall specific consumptions through a substantial reduction of the hoods’ drying contribution.

The TT SYD has a 3,200 mm diameter, a face length of 2,920 mm and it features Toscotec’s patented deckle insulation system, which ensures high thermal energy efficiency and maximum safety. The scope also includes the steam and condensate removal system, steam joints, bearings and housings. Toscotec will deliver a complete service package including engineering, erection supervision, onsite training, commissioning and start-up assistance.

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C. Y. P. Del R. S.A., said, “This investment aims at increasing the effectiveness of our operations. We chose TT SYD based on its great reliability and superior energy efficiency. When we selected the supplier for this rebuild, we were looking for the best solution to increase our production capacity. Toscotec customized the equipment specifically for our needs and offered us the possibility of reducing our manufacturing cost as well. This winning combination represents a key asset to sustain our growth.”

Gabriele Romanini, Sales Manager at Toscotec, said, “We are happy to begin this cooperation with Cartones Y Papeles Del Risaralda. We are confident that TT SYD will meet their expectations in terms of superior drying capacity and energy efficiency, providing them with a competitive advantage in the market.”

Toscotec is the global market leader of Steel Yankee Dryers. Over 200 TT SYDs are currently operating all over the world, contributing to the build-up of a substantial database of different operating conditions, which drive and advance Toscotec’s expert services and continuous engineering progress on steel Yankee dryers.

About C. Y. P. Del R. S.A.

Established in 1968, Cartones Y Papeles Del Risaralda is a family-owned company that manufactures toilet tissue, napkins, kitchen rolls and towels. Headquartered in Risaralda, in Western Colombia, it has an annual production of approximately 30,000 tons of high-quality tissue for the consumer and AfH markets, which it distributes in the domestic and Latin American market.

For further information, please contact: Marco Dalle Piagge, Sales Director, Toscotec Tissue division, This email address is being protected from spambots. You need JavaScript enabled to view it. Gabriele Romanini, Area Sales Manager, Toscotec Tissue division, This email address is being protected from spambots. You need JavaScript enabled to view it.

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Toscotec will rebuild two tissue machines in Western Europe and Africa for a leading tissue manufacturer that remains confidential. The projects are on a turnkey basis and are scheduled for completion in 2021.

For the project in Europe, Toscotec will supply the tissue machine’s broke line and pope reel section, and its newly designed OPTIMA slitter rewinder, which ensures the preservation of tissue quality and high winding efficiency.

The supply of the project in Africa includes a modification into crescent former configuration, which will replace the existing machine’s forming and felt sections.

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The provision of engineering design, dismantling operations, erection, commissioning, start-up, and training services, ensures a full-on turnkey supply for the rebuilds.

Toscotec further strengthens its position as leading supplier of tissue rebuilds, building on its substantial expertise in customizing its design to the mill’s requirements, supplying turnkey packages, and delivering on the tight schedule of machine shutdown periods.

Gabriele Romanini, Toscotec Sales Manager, comments: “The rebuild market is key to Toscotec, because it allows us to do what we do best, that is tailoring the machine configuration and our entire design to the specific needs of the customer, optimize their production to achieve the maximum possible capacity and energy efficiency. These new projects are no exception. Today, we are still seeing an untapped potential for rebuilds, with producers looking into increasing the efficiency of their older machines.”

For further information, please contact: Marco Dalle Piagge, Sales Director, Toscotec Tissue division, This email address is being protected from spambots. You need JavaScript enabled to view it. Gabriele Romanini, Sales Manager, Toscotec Tissue division, This email address is being protected from spambots. You need JavaScript enabled to view it.

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Two Toscotec-supplied AHEAD 2.0L tissue machines came online at Sofidel America’s mill in Inola, Oklahoma. Shortly after start-up, the two lines met Sofidel’s quality standards, and have been running at a high operation efficiency, producing premium quality tissue.

In spite of the Covid-19 pandemic and the challenges it posed, Toscotec and Sofidel went the extra mile and managed to successfully complete the project in record time.

Toscotec delivered a turnkey plant including two AHEAD 2.0L machines of 5500 mm sheet trim width, 2000 m/min operating speed, each producing 60,000 tons/year. These machines are equipped with TT SYD Steel Yankee Dryer and high-efficiency TT Hoods, designed for a high level of energy recovery.

The supply also included the stock preparation system, Toscotec’s patented TT SAF (Short Approach Flow), the DCS and QCS, as well as the dust and mist removal systems. Toscotec also supplied the boiler plant, the compressed air station, the bridge crane, the shaft puller, the roll handling and wrapping systems, the chemical preparation system, the hall ventilation system, and the water treatment plants.

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The supply also included the stock preparation system, Toscotec’s patented TT SAF (Short Approach Flow), the DCS and QCS, as well as the dust and mist removal systems. Toscotec also supplied the boiler plant, the compressed air station, the bridge crane, the shaft puller, the roll handling and wrapping systems, the chemical preparation system, the hall ventilation system, and the water treatment plants.

Luigi Lazzareschi, CEO of Sofidel, says, "Today’s achievement steps up Sofidel’s strategic coverage in the U.S. market. Technological innovation is key to our Group. It allows us to deliver the product quality and safety that build consumer trust, and it makes us honor our long-term commitment to sustainability. I applaud the hard work and strong cooperation of Sofidel and Toscotec that made today’s success possible."

Alessandro Mennucci, CEO of Toscotec, says, "It is a great satisfaction to see that two top-of-the-line Toscotec machines achieved great performances at Sofidel America. This excellent result rewards us for all the efforts that our teams made together over the past three years. We look forward to continuing this important partnership with Sofidel in the coming years."

The Sofidel Group

The Sofidel Group is one of the leading manufacturers of paper for hygienic and domestic use worldwide. Established in 1966, the Group has subsidiaries in 12 countries – Italy, Spain, the UK, France, Belgium, Germany, Sweden, Poland, Hungary, Greece, Romania and the USA – with more than 6,000 employees, net sales of 1,919 million Euros (2019) and a production capacity of over one million tonnes per year (1,308,000 tonnes in 2019). “Regina”, its most well-known brand, is present on almost all the reference markets. Other brands include: Softis, Le Trèfle, Sopalin, Thirst Pockets, KittenSoft, Nalys, Cosynel, Lycke, Nicky, Papernet. A member of the UN Global Compact and the international WWF Climate Savers program, the Sofidel Group considers sustainability a strategic factor with regards to growth and is committed to reducing its impact on natural capital and maximising social benefits, setting as objective the creation of shared added value for all stakeholders. Sofidel’s greenhouse gas (GHG) emissions reduction targets to 2030 have been approved by the Science Based Targets initiative (SBTi) as consistent with reductions required to keep warming to well-below 2°C, in line with the goals of the Paris Agreement.

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Italian tissue manufacturer EuroVast fired up a new MODULO-PLUS tissue machine supplied by Toscotec at its Cartiera della Basilica paper mill in Villa Basilica, Lucca, Italy. PM5 is running efficiently at the speed of 1,600 m/min and since its start-up in February, it has exceeded the project’s production targets with excellent results in energy consumption

The new line completely replaced the mill’s existing PM5, a suction breast roll machine. The sheet width is 2,770 mm and the production capacity is over 30,000 tpy. It is equipped with a single press TT BlindDrilledPressRoll, a TT SYD and gas-fired TT Hoods. PM5 produces toilet tissue, kitchen towels and napkins from 100% pre-dried virgin pulp. EuroVast also purchased a complete service package including dismantling operations, erection, training, commissioning, and start-up assistance. 

This is a repeat order for Toscotec, who in 2015 supplied another MODULO-PLUS tissue line to EuroVast’s Cartiera della Basilica mill in Lugliano, near Lucca. This new line will increase the Group’s production capacity to 150,000 tons/year.

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Vincenzo Romano, owner of EuroVast S.p.A., says, “EuroVast supports its growth by investing in advanced technology. We also want our growth to be sustainable for the environment that is why we keep our focus on energy efficiency. PM5 meets our standards for quality and production, and our energy consumption targets. We have worked with Toscotec for many years, today’s achievement is the outcome of the good cooperation between our teams.”

Alessandro Mennucci, CEO of Toscotec, says, “Our partnership with EuroVast Group dates back over 20 years. That is why we are particularly pleased to see another Toscotec machine running efficiently at their mill today. EuroVast has very high standards of product innovation and quality and I believe that the performance and flexibility of this tissue line will meet their needs and serve as a key asset to support their growth in the market.” 

About EuroVast S.p.A.
Founded in 1992, EuroVast is a Tuscan-based tissue producer headed by Vincenzo Romano and his son Umberto. It operates five tissue mills in Italy and three converting plants across Europe, one in Lucca (Italy), one in Oss (The Netherlands) and one in Liverpool (UK). EuroVast owns the renowned Fior di Carta, Suprema, Buffalo and Bravo brands that make up 40% of its sales revenues, while private labels account for 60% of its market. The Group employs about 300 staff and turns more than 170 million EUR (2019). 

For further information, please contact:
Marco Dalle Piagge, Sales Director, Toscotec Tissue division, This email address is being protected from spambots. You need JavaScript enabled to view it.
Riccardo Gennai, Sales Manager, Toscotec Tissue division, This email address is being protected from spambots. You need JavaScript enabled to view it.

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