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The iDEAL® mod. 2000S Tissue Machine start-up took place on March, 20th in Mexico, perfectly in line, even in advance, compared to the challenging project scheduling and despite the very critical global conditions

The new A.Celli iDEAL® Tissue Machine machine has a 2650-mm web width, a working speed of 2000 m/min and a production capacity of about 100 tpd. It was designed to answer all the requests and demands made by Grupo Corporativo Papelera, who with this step forward made its strategic investment in the world of tissue paper production thanks to a high-performance machine.

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The scope of supply represents the state of the art of A.Celli technology, in particular with the following great innovations:

  • 16’ Forged Yankee, innovative and unique on the market, consisting of a single piece of steel heated to more than 1200 ° C, moulded and processed using forging and hot rolling systems, from which a cylinder of homogeneous material without welds is obtained.
  • Extreme Automation DCS System, completely new, intuitive and user-friendly that has allowed the customer to manage the machine autonomously from the very first day, always with the prompt remote assistance of A.Celli technicians.

The A.Celli team showed great flexibility, managing to complete a highly customized project on an engineering and assembly level.

Despite the very critical global conditions and with the extraordinary support and expertise of the Grupo Corporativo Papelera’s staff, the A.Celli team did not lose concentration, being able to manage the paper to the pope and make the first reel a few hours after the ignition.

With this new Tissue Machine A.Celli Paper will offer Grupo Corporativo Papelera a leap forward in quality, aiming for important and ambitious production milestones.

The long-standing competencies, dependable reliability and technological excellence that have always distinguished the Group make A.Celli Paper the ideal supplier for every customer.

Published in South American News

Kimberly Clark Products Malaysia, Kluang Johor Mill: A.Celli concludes the scheduled upgrade of the TM2 Tissue Line with a new off-line shaft puller and a new set of expandable spool, in combination with the upgrade of the rewinder slitting unit

After the upgrade of the TM1 rewinder and other tissue line equipment, A.Celli Papers Customer Service team installed and successfully concluded the upgrades on the TM2 tissue line.

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The intervention entailed updating the core handling system downstream the TM2 pope reel with the supply of the A.Celli off-line shaft puller. Since this an automated process, it allows the customer to improve and accelerate the shaft extraction from the mother roll and to improve KC Products Malaysia personnel safety. The rebuilding of the TM2 line has been completed with the upgrade of the Rewinder slitting section with a modern and efficient knives system.

A.Celli Paper worked in close contact with the customer, finding the optimal solution for a light-impact modification with a short shutdown time. The new configuration kept into consideration the convenience of the operations that had to be carried out on one hand and the needs of KC Products Malaysia on the other, in order to obtain the best results in terms of efficiency.

The customer was very appreciative of the project, acknowledging the high level of professionalism of A.Celli Paper’s Customer Service team and its ability to find functional, practical and intelligent solutions through engineering and design analyses.

A.Celli Paper is capable of offering prompt and effective consultancy in-line with any type of investment and production demand.

Contact us for a consultancy or a dedicated project.

Published in Asian News
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Last February 28, at the Chinese plants of SUNSHINE New Material for Hygiene and Health Care Jiangyin Co. Ltd. Located in Jiangyin, two machines for Spunlace product, a winder and a rewinder installed on two different lines side by side, have been started up.

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A.Celli supply, specifically tailored to the specific needs of the customer, includes:

  • E-WIND® STREAM Master Roll winder of 3600 mm capable of handling reels up to 2500 mm in diameter, with basis weights ranging from 30 to 100 gsm and with a maximum operating speed of 200 m/min, specifically designed for carded products and to guarantee maximum reliability and minimal maintenance
  • E-WIND® RAPID off-line slitter rewinder of 3600 mm, calibrated for reels with a maximum diameter of 1200 mm, with basis weights ranging from 30 to 100 gsm and with an operating speed of 800 m/min. Among the optionals we can find the "DSS" (defect stop system), a system able to monitor any defects on the reel, report them and give the possibility to remove them if necessary, and the “Slittomatic®”automatic slitting units positioning.

Once again, the long-standing expertise and experience of A.Celli Nonwovens and the particular attention to the customer have made possible the success of the project for the Chinese group SUNSHINE New Material for Hygiene and Health Care Jiangyin Co. Ltd.

Published in European News
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A.Celli Nonwovens SpA is honored to continue the fruitful collaboration with Karweb Nonwovens thanks to the supply of a winding line dedicated to the production of Spunlace

Karweb Nonwovens, a division of the KARA Holding Co. and one of the major player active in the production of Spunlace and Airlaid, has renewed, after a first order made in 2016, the trust in A.Celli and its cutting-edge solutions in the nonwoven market.

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The installation and start-up of the line, which will take place in the Turkish plant of Karweb Nonwovens located in Gaziantep, are scheduled for early 2021. A.Celli's supply includes a “Stream” Master Roll winder, an off-line slitter rewinder “Rapid” with an operating speed of 800m/minute and equipped with trim suction system, a shaft handling solution with "easy core" positioning device and a finished reel handling and packaging system.

A further confirmation of the customer's trust in A.Celli Nonwovens technology, that thanks to this supply proves, as always, to be at the cutting edge of the market and able to satisfy any type of requirement with flexibility and readiness.

Published in European News
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A.Celli Group is pleased to announce that Massimo Ardito has been appointed as the new General Manager of the American branch A.Celli International with effect from March 9, 2020.

As General Manager, Massimo Ardito will be in charge of the management of A.Celli International and the development of new sales and customer care strategies, seizing the current market needs to generate further growth and business opportunities.

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Before joining the A.Celli group, Massimo Ardito has accumulated many years of experience in the flexible packaging sector, with the opportunity to play different roles in multicultural environments in which he had the chance to develop customer relationships, enrich his technical and commercial know-how and at the same time apply business strategies that led him to reach ambitious goals.

We welcome Massimo aboard and wish him to achieve great goals together with the A.Celli Group Team.

Published in European News
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A.Celli developed the Dust Removal System with the aim of removing issues caused by dust loads in the slitting area

Nowadays dust issues are becoming more and more a prime concern, especially for hygienic fabric producers, high speed spunmelt production lines and other lines sensitive to the aforementioned issues, such as Spunlace, Airlaid and Meltblown ones.

In fact, dust deposition in the slitting area may reduce the cutting efficiency, contaminating the finished product and contributing to environmental pollution. In order to reduce the dust originated by the slitting processes in the rewinding section, A.Celli designed an efficient Dust Removal System.

A.Celli Dust Reduction System

This solution can be installed on in-line slitting winders, rewinders, spooling lines and printing lines, and it consists mainly of individual suction heads positioned on the knife holder and equipped with a blower system to remove dust accumulation on the knives. Other parts of the system are the suction line, a fan equipped with an inverter and a control unit, pipes and ducts to convey dust and air to the fan and a filter for dust/air separation.

There is also the possibility to add suction nozzles over the knives to increase the efficiency of the system.

The A.Celli Dust Removal System guarantees minimized dust loads on products and winders, expanded cleaning intervals, more production hours, the reduction of maintenance activities and the extension of the machinery useful life.

Furthermore, minimizing the dust in operational areas actually supports people’s health and safety.

Contact us for a consultancy or a dedicated case study

Published in European News
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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

A.Celli Group is pleased to announce that Eng. Fabrizio Tonello has been appointed to the technical management of A.Celli Paper with effect from January 7, 2020.

As Technical Director (TD), Tonello will be in charge of managing the technological development, identifying and implementing new product strategies and market opportunities, sharing the already started digital transformation process of the commercial offer of A.Celli Paper S.p.A.

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Eng. Fabrizio Tonello has a Nuclear Engineering degree from the Polytechnic of Turin and has gained many years of experience in the tissue and paper sector, covering key roles in the staff of important industrial companies such as PMT Italia Srl and Beloit Corporation.

 “I am sure that Fabrizio will be able to carry out this task in an excellent way, guaranteeing the quality of project management and the achievement of the business objectives.” says Mario Fazzi on behalf of A.Celli Group.

We welcome Fabrizio aboard and wish him to achieve great goals together with the A.Celli Group Team.

Published in European News

Artificial Intelligence (AI) is the ability for a machine to take in information, analyze it and come to conclusions based on that analysis, and it is taking the world by storm. The idea behind AI is that we can program a machine to mimic the learning and decision-making capability of humans, therefore allowing us to automate processes.

AI has many applications nowadays, such as:

  • speech recognition;
  • facial recognition;
  • medical diagnosis;
  • automated customer support;
  • machine learning and deep learning

The AI global market share is expected to reach nearly $170 billion by 2025 and this technology is being adopted by numerous industries, including:

  • healthcare and medicine;
  • education;
  • human resources;
  • marketing;
  • finance;
  • retail and eCommerce;
  • public relations;
  • manufacturing.

Industry 4.0 How deep learning can help you recognize paper and nonwoven machine defects

According to a McKinsey survey, 47% of respondents say they have incorporated at least one AI capability into their business operations. Within the manufacturing sector, AI, specifically machine learning, is being used on the factory floor. In particular, it has specific and impressive application when it comes to machine operations and maintenance.

Deep learning: how it works

Deep learning is a subset of machine learning. The latter uses an algorithm to analyze data, detect patterns in those data, learn from them and adjust processes and operations accordingly, without the need for human intervention. Usually, machine learning requires a structured and labelled data set to use as a reference for the analysis, and this is referred to as supervised machine learning. However, this poses limitations, which include the tediousness of labelling data, data bias, and difficulty in transferring what is learned in one situation to another.

When it comes to Deep Learning, these limitations are minimized because this is a form of unsupervised machine learning that does not require a structured and labelled reference data set.

While both types of machine learning are useful in an industrial setting, Deep Learning is particularly useful when it comes to exploring raw data and making inferences that will reveal hidden structures within those data, and this is highly relevant when it comes to machine operations on the tissue and nonwovens production line.

How deep learning is used to identify machine defects

On the production line, machines operates around the clock and under extreme pressure, and obviously they experience wear over time that can easily result in unexpected breakdowns and idle times that negatively impact production.

Read more: 4 Tools for Tissue and Nonwovens Machines to Reduce and Optimize Idle Times

This loss of productivity can, in turn, seriously impact profits. However, until now, workers on the production line had no way of monitoring machinery at a detailed level during operations. Getting close to machinery when it is working poses a safety risk and many critical machine parts are not within the line of sight of workers.

Thanks to Industry 4.0, smart machines outfitted with sensors that transmit real-time operational data over the cloud are becoming increasingly common. Hundreds, even thousands of data points flow in every minute and these data are received by a machine-and-software-independent platform, where the data will be integrated and analyzed thanks to machine learning.

It is important to understand that the data that flows in are chaotic and raw. Deep Learning can take these data and separate them into layers that forms the structure of the neural network, such as the input layer, hidden layer, and output layer. Deep Learning neural networks can analyze the data over time to map the degradation of machine parts and machine function and determine when any machine part is coming close to the end of its lifecycle.

Subsequently, predictive maintenance can be scheduled such that a particular machine can be taken offline at the most advantageous time. This will ensure that operations will continue to run smoothly and at optimal levels without abrupt interruptions.

Deep learning for better tissue and nonwovens machine productivity

Minimizing machine downtime is one of the most important factors to ensure that tissue and nonwovens production lines remain at optimal levels of operation. Deep learning is an AI tool that is leading the way in the detection of machine defects that are not visible to workers on the production line. These defects can be caught in time to schedule predictive maintenance in order to avoid unplanned machine idle times and loss of profit.

For more information about how AI, deep learning, and automation can improve productivity on your tissue and nowovens production line, download our eBook “5 Industry 4.0 Tools that Boost Productivity in the Tissue Paper and Nonwovens Industry”!

Published in European News
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The Chinese group Shan Don Sun Honghe Paper Industry Co., Ltd. has purchased three more A.Celli E-WIND® P-100 Rewinders, this time for the subsidiary Sun Paper Savannakhet Co., Ltd., for a project in Laos located in Xepon, province of Savannakhet.

The almost twenty-years partnership between this important Chinese group and A.Celli Paper is further strengthened.

The three E-WIND® P-100 Rewinders will handle Medium Liner Board rolls, 6730mm wide.

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Two Rewinders will be positioned downstream of a first Paper Machine that produces paper (basis weight 140-250 gsm), while the third Rewinder will be placed at the service of a second line that produces paper, whose basis weight is 100-160 gsm.

All these three Rewinders have a design speed of 2500 mpm and are equipped with unwinders in-line to the Paper Machines, Automatic Spool Storage and new Slittomatic® Web-in cutting systems.

This order follows the one of the Rewinder sold at the beginning of the current year for the Shandon plant, already started-up and producing for several months.

The customer has also involved A.Celli Paper in some upgrades on the slitting groups of Rewinders supplied in the past: this type of activity will allow the Chinese group to obtain a higher efficiency with the relative modernization of its machinery.

Published in Asian News
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