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Valmet and Fabio Perini have established an Industrial Internet ecosystem partnership to strengthen collaboration in the tissue industry. The target is to allow tissue producers and converters to work together more efficiently, and to exchange knowledge and resources for the benefit of their customers.
The partnership combines Valmet's comprehensive tissue making technology and process optimization know-how with Fabio Perini’s strong expertise in complete solutions for converting and packaging machines as well as in the converting process and technology. The two companies’ solid expertise combined with data from tissue mills and converting plants will provide a new dimension to tissue mill optimization.
The collaboration aims at providing an unbroken chain of production data from the tissue machine to the converting line and utilizing artificial intelligence-driven applications in the tissue production process to make the converting operations downstream more efficient. This will bring significant mill-level quality and efficiency improvements for tissue producers and converters.
“Starting from customer needs, Valmet and Fabio Perini are now taking the first steps to develop solutions where innovation goes beyond company borders, covering both tissue production and converting processes. Through collaboration with our common customers we can provide new digital solutions and services to help move tissue mills’ performance forward,” says Jari Almi, Vice President, Industrial Internet, Valmet.
“We believe an open innovation model is a key concept through which companies within tissue business can create different partnerships to make their innovation process more efficient, as well as exchange knowledge and resources. By combining the strengths of our companies, we can facilitate broad innovation and fast adaptation, enable new business and service models and help improve the profitability of companies in the tissue business,” says Oswaldo Cruz Junior, CEO of Körber's Business Area Tissue.
Both Valmet and Fabio Perini have a long history in offering measurement and optimization applications for tissue production. These reliable measurements have provided proven results for their customers.
Information about Fabio Perini
Fabio Perini S.p.A. with the brands Fabio Perini, Casmatic and Concept X, is specialized in the production of machinery, lines and integrated systems, for the converting and packaging of tissue paper, for a wide range of products: toilet rolls, kitchen towels, industrial rolls. Founded in 1966 at Lucca, the Italian district of tissue production and converting technology, Fabio Perini is a point of reference for its high level of innovation and advanced technology. Fabio Perini S.p.A. is the leading company of the Körber Group’s Business Area Tissue. www.fabioperini.com
Valmet is the leading global developer and supplier of process technologies, automation and services for the pulp, paper and energy industries. We aim to become the global champion in serving our customers.
Valmet's strong technology offering includes pulp mills, tissue, board and paper production lines, as well as power plants for bioenergy production. Our advanced services and automation solutions improve the reliability and performance of our customers' processes and enhance the effective utilization of raw materials and energy.
Valmet's net sales in 2018 were approximately EUR 3.3 billion. Our more than 13,000 professionals around the world work close to our customers and are committed to moving our customers' performance forward - every day. Valmet's head office is in Espoo, Finland and its shares are listed on the Nasdaq Helsinki.
Read more www.valmet.com
Fabio Perini S.p.A. Brazil is enlarging its administrative offices in Joinville and its production plant to handle the increasing demand from the Brazilian and South American market for tissue paper and folded paper products.
“Brazilian and South American markets today are rapidly expanding and show a higher long-term growth rate than more mature markets like those in Europe and the US”, comments Dineo Eduardo Silverio, Chairman of Fabio Perini Ltda. “In South America, the tissue paper market has been growing by at least 3% a year, and we estimate a growth of around 15% over the next five years”.
The enlargement of the Joinville plant is also marked by the entry of MTC, technology leader in solutions for folded tissue products, in order to answer growing market demand in the tissue field from all over South America.
In late November 2019, an Open House was set up at the Joinville premises, where visitors could see in function, the first MTC machine made entirely in Brazil. A strategic move that aims at reinforcing the company on the market, increasing its competitive edge and providing on-site sales and after-sales services.
“Part of the growth of the tissue market comes from increased consumption of folded paper products, and one of the reasons which drove us to bring MTC technology into Brazil was to answer this growing demand: surely one of the main requests coming from the Latin American and South American market is for machinery to produce folded tissue paper products. In the coming years, we expect a further upward push”, says Dineo Eduardo Silverio.
In late July 2019, Roll-Tec, Brazil’s specialist in rolls for embossing and tissue production, was bought by the Körber Group’s Tissue Business Area. The purchase was intended to develop and reinforce the position of tissue on the Latin American market, driving Fabio Perini Brazil to study market expansion strategies in North America as well, in an effort to consolidate and expand their leadership in the Americas.
Over 1000 machines all over the world connected to the Lucca Control Room for real-time line control
Fabio Perini presented at MIAC the Tissue Performance Center, a next generation technologic environment where expert engineers, supported by company data scientists, continuously register and analyze customers’ data to supply information on the machines status and suggest improvements to maximize the overall equipment effectiveness (OEE) of the production lines.
Thanks to a direct connection with the customers’ machines, the Tissue Performance Center can now work proactively, not just reactively as it used to in the past. The on-line visualization of operating parameters allows a continuous evaluation of their status and helps pointing out potential anomalies.
“The customer connects his machine to the Tissue Performance Center - Franco Franceschi, Customer Service Performance Services Manager, explains – This way, output data, engines’ temperature and parameters’ settings are kept under constant monitoring. These values, compared also with historic production data, allow the Fabio Perini experts not only to remotely implement corrections to enhance the efficiency of the production lines, but also to detect possible causes of malfunctioning and to establish beforehand the appropriate actions to solve them.
Performance reports, background analyses to evaluate cause/effect and now also control on energy consumption are part of an articulated path – Franceschi concludes – that will lead us in the near future to a learning machine capable of autonomously interpreting data and of improving by its own the machine performances under every condition”.
Big news at Fabio Perini, as the company presents at MIAC, in absolute world premiere, the prototype of a totally ecologically sustainable, coreless and glueless kitchen roll.
“With this prototype - Enrico Zino, Fabio Perini Head of Marketing, declares – we provide the answer to three market requirements: delivering our clients as much product as possible without increasing bulkiness and without giving up quality; reducing waste consequent to core disposal, maintaining the product’s structural characteristics across the whole logistic chain; and turning out a 100% ecologic product”.
“Up to this time - Zino points out – several technologies had made possible an “environment friendly focus” limited to certain production phases: doing without the core for our rolls, eliminating glue or focusing on replacing plastics in packaging. Now, Fabio Perini is the first in the world to present a prototype of kitchen/towel roll combining already existent technologies with an absolute novelty, just patented and which will be moving to the industrial phase shortly after MIAC, that is, water lamination also for kitchen rolls”.
Fabio Perini has always had a green vocation, which in the past prompted the launch on its markets of ecofriendly solutions, even anticipating trends.
In 2010, Fabio Perini was the first company to propose gluefree solutions, barring the use of glue both in lamination (Aquabond) and in the initial pickup f tissue around the core (Web Tuck system Rewinder), reducing environmental impact and saving the cost of glue and the ensuing maintenance; it launched on the market the patented Solid and Solid+ coreless technology to produce full rolls that can keep the product’s structural characteristics, increasing by 16% the amount of tissue per roll with the same diameter, and attaining a 10% reduction of packaging required for the same amount of product transported. In addition, Fabio Perini recently presented a series of packaging solutions based on paper coupled with ecologic bioplastics, derived from vegetable starch and waste, creating a product whose characteristics are comparable to those of plastic polymers. This 100% compostable packaging can be processed maintaining the machinery speed at almost the same speed as with polyethylene production.
To all this, Fabio Perini is adding several solutions to limit the energy consumption of its machinery thanks to high efficiency engines and inverters, which consume less and have regenerative feedback capabilities, hybrid energy control-panel cooling, led lights drastically reducing the lighting energy absorption, inside the machines and the control-panels.
“The definition of sustainable development dates back to 1987 - Enrico Zino, Fabio Perini Head of Marketing, declares – but while at that time companies who embraced a growth compatible with environmental preservation were doing so by choice, today, as we become aware that our planet can no longer compensate the deep impact of our production and lifestyle, it has become a duty and a responsibility for all. For us at Fabio Perini – Zino concludes – nature and technology represent two sides of the same coin: nature is a perfect technology and our technology must be perfect for nature. We aim at offering, even at industrial level, a more and more sustainable business, by acting as key partners for all the companies that give the utmost priority to environmental compatibility”.
Replace plastic packaging with a new eco-friendly, combined paper and bio-plastic material on Casmatic packaging machines.
Plastics are the most used materials in the world of packaging, but they need to be limited in light of recent restrictions of the European Commission concerning disposable products. In response, Fabio Perini has developed a "green" primary and secondary packaging solution that can easily adapt to current systems and existing equipment. This provides cost efficiencies for Fabio Perini customers and helps them actively contribute to safeguarding the environment while keeping up with technology and productivity.
To accomplish this, Fabio Perini had to identify the most suitable alternative to plastic for primary packaging. This material had to be not only eco-sustainable, recyclable and/or compostable, but also as versatile as the polyethylene in terms of abundant availability, product protection, packaging options, printability, and resistance to production-related mechanical stress.
Fabio Perini and a partner company conducted numerous materials tests on the latest generation packaging machines such as the CMW1000 and Carbon T, and ultimately developed an innovative, totally ecological material that combines paper and bioplastic to form properties that can be interchanged with normal polyethylene.
The new Paper Packaging Solution addresses the facts that paper alone is not strong enough and water-repellent for primary packaging and that bioplastic alone is not economically viable for use on an industrial scale. Paper Packaging Solution is a paper coupled with Mater-Bi, a totally ecological bioplastic having the same properties as plastic polymers, but with the added benefits of being recyclable, biodegradable, and compostable.
Two different types of Paper Packaging Solution products are available: a low-weight paper, 25 gm2, and a thicker paper, 40 gm2. Both are FSC-certified and are laminated or extruded with bioplastics with thicknesses ranging from 7 to 9 microns to ensure high pack weldability and an excellent product hygroscopic barrier.
Further, Paper Packaging Solution products are available in virgin paper or recycled paper. The 100% biodegradable virgin paper is certified "Vinicotte OK compost," which has the fibers closely joined to accommodate the higher heat needed for bioplastic fusion and perfect packaging seals, as well as being more resistant. The 100% recyclable and compostable paper has looser fibers. The
heat passes through it more easily to create package seals, but the looser fibers affect its resistance.
Paper Packaging Solution products are fully compatible with Casmatic's latest generation packaging machines — such as Casmatic A6T, CMW1000 and the new Carbon T — thanks to the "bio-pack kit." This innovative device makes it is possible to select the desired type of packaging material from the control panel and the Casmatic packaging machine automatically sets various parameters, including heat and time, required to perfectly seal the packages according to the packaging composition.
Mr. Mauro Luna appointed Fabio Perini S.p.A. new Global Sales Director. After graduating in Mechanical Engineering at the University of San Paolo in Brazil, Mr. Luna completed his studies by attending a course in Marketing at the University of Berkeley in California and a Master of Business Administration in Brazil. He has developed a professional career in Sales, starting as Sales and Application Engineer with Voith Brazil and, in the following years, worked as Sales Director, Marketing and Business Development with SKF, where he had the opportunity to take up the role of Chief Executive Officer of SKF’s branch in Peru. His last job was as Commercial Director for Amcor Rigids Plastics. Mr. Luna will lead Fabio Perini’s Sales department at global level.
“He will enhance Perini’s existing markets and customers” says Oswald Cruz CEO of Fabio Perini S.p.A. “and thanks to his many years of sales experience and his knowledge of different contexts he will lead the Global Sales of Fabio Perini to understand the current needs of the market, and to be closer to each journey of our Customers with our products and services”.
Fabio Perini Digital Tissue™: in 6 months over 130 lines worldwide, connected with the Lucca headquarters for a constant control of fact-based production. The future? A line integrated with the whole plant and the global tissue ecosystem
Six months after its disclosure, Fabio Perini Spa takes stock of Digital Tissue™, the suite of digital solutions for the tissue ecosystem aimed at optimizing the overall equipment effectiveness (OEE) of the lines: as of today, over one hundred thirty lines all over the world (between Europe, the Americas, Asia and Africa) are connected to the Lucca headquarters allowing to constantly control the fact-based production thanks to a “graphic thermometer” which keeps the customer and Fabio Perini engineers up-to-date on the machines’ status in an intuitive way.
“The aim of Fabio Perini – Antonio Mosca, Head of Fabio Perini S.p.A Digital Transformation, comments – is not only to be a supplier of converting and packaging lines, but also to offer a complete digital proposal, with smart software and controllers which, by collecting the data directly from the machines, can allow management of the whole production line, optimization of the output and definition of specific KPIs”.
“With Tissue Data Cloud – Mosca adds – we have concretely demonstrated the potential of the new digital services to our customers. Data collection and analysis, processed into easy and intuitive indicators, offer immediate evidence of the machines’ performance, while the detection of irregular trends allows our technicians to put in place immediate actions to recover the efficiency of the production line. However, our objective is to go beyond emergency rescue, that is to be able to predict potential anomalies and propose a “treatment plan” personalized for each customer”.
The future of Digital Tissue™ is not limited to single machines or lines. “We want to see the machine integrated with the line and we are preparing to receive data both upstream and downstream from the machine, so as to realize an integrated OEE for the line, all the way to being able to analyze the performance of the whole plant. Our dream - and an operational plan already exists to realize it - is to integrate the plant with the overall production chain, from the tree in the forest to the tissue roll in the household”.
Digital Tissue™ revolves around four pillars:
Tissue Data Cloud
Data processing through several performance indicators offers the customer immediate visibility of the critical steps of the process. By using a dashboard, directly accessible from the Fabio Perini Customer Service Portal using PC, Tablet and Smartphone, the data of the lines are processed in an easy and intuitive way. Thanks to the analysis of these indicators and to the expertise of the company technicians, customers are offered a real Digital Audit enabling them, even remotely, to detect the causes of line malfunctions and to establish ahead of time the actions to solve them.
Process control is a service and solutions package which now can be installed not only on all the new converting lines, but also on installed bases already operating in production. Thanks to Process Control, the tissue ply and the finished product can be measured and the data collected to be converted into information that is useful for productive efficiency.
All-in-One is the Smart Application that allows automatic management of the change of format of the whole line by communicating the type of recipe and the configuration of production parameters. In addition, All-in-One manages the line’s output flow and can modify the speed of each machine by modulating the capacity of the accumulator, allowing the operators to act without interrupting production.
Condition Monitoring is a solution for predictive maintenance that, thanks to vibrational analyses, pinpoints possible anomalies or deviations from planned patterns, allowing to plan maintenance on the basis of the actual status of the equipment and avoiding untimely stops or unnecessary replacements.
Digital Customer Service,
The WECARE platform together with the processing and analysis of production data, combined with the technical expertise of the Fabio Perini staff, enables customers to preserve the value of their capital asset over time and to optimize the Overall Equipment Effectiveness (OEE) of their lines.
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The Joinville, Santa Catarina, site honored with the prestigious award for 2018
Fabio Perini Brazil, a branch of Fabio Perini S.P.A., a leading global supplier of machinery and services for tissue converting and packaging, gained a place of honor in the authoritative ranking of US Institute “Great Place to Work® Certified” which since the ‘90s has been implementing the worldwide ranking of the best places of work all over the globe. Fabio Perini Brazil gained 11th place in the regional ranking of mid-range companies.
The mission of the Great Place to Work Institute is evaluating companies’ working conditions and management of service suppliers. Through employee and employers’ surveys, the people management, the workplace and the employees’ confidence are evaluated, and a ranking is elaborated on the basis of indicators of credibility, respect, impartiality, pride to belong.
Silvana Dellacqua – Human Resources Manager of Fabio Perini – pointed out the company’s utmost attention towards human relations and resource development: “We keep investing in technical training and language support, in order to promote more effective communications among employees, and over the years we have developed an efficient network of relationships among different teams. In addition, the existing communications channels allow our employees to contribute their suggestions to enhance collaboration, therefore stimulating people’s interest and involvement.”
“I wish to congratulate everybody for this achievement – commented Dineo Silverio, Company President for Brazil and South America - People are what makes the difference in growing a business. A high level of internal satisfaction reflects itself automatically in the satisfaction of the customers in our market. Employee management is a strategic factor for the evolution of our business, because the satisfaction to be working for a company translates into greater efficiency and better quality of the final product”.
This important milestone confirms the high quality of Fabio Perini S.p.A., which enters with full rights in the international community of the “Great place to work” certified companies.
Gianfranco Agnusdei, Global Customer Service Director: “More efficiency and less costs. This is the objective of customer service: help our customers in preserving over time the value of their capital asset”
Fabio Perini S.p.A. took part in MIAC, where during the convention “Towards Converting Tissue 4.0” Gianfranco Agnusdei, Global Customer Service Director, disclosed the new company strategy and presented the best available technologies to enhance performances, quality and management of the production process.
“Industry 4.0 for our company has its own application even in customer service, –Gianfranco Agnusdei comments – a field where the use and analysis of production data, together with the technical expertise of Fabio Perini’s people, allow customers to preserve over time the value of their capital asset and optimize the Overall Equipment Effectiveness (OEE) of their lines. Digital services are not limited to lines and systems supplied by Fabio Perini, but they can be used on equipment by other producers as well."
Three years ago, Fabio Perini launched its Customer Service Portal, which has evolved becoming the customers’ digital touch point, with information on their installed base, the history of maintenance services, the suggested equipment modifications and a web shop for spare parts, placing orders directly online. Today the Portal becomes also the tool to activate and monitor line performance using two solutions, Tissue Data Cloud and Digital Shift Support.
The Tissue Data Cloud processes data based on a wide set of performance indicators, so as to offer the customer immediate visibility of the process critical points. Thanks to the Web Dashboard, the values of the line are re-elaborated easily and intuitively and available in real time for the production manager.
The second new feature is the Digital Shift Support, also activated from the Portal and available on the operator’s tablet. The Digital Shift Support is a smart application that collects, together with a minimal set of performance indicators, the production speed and the justifications of alarms by the operators.
“Up to now our path has been going through digitalization, from equipment alarm detection to production indicators analysis, so as to identify inefficiencies and be able to act on specific line sections. – Agnusdei goes on – But we at Fabio Perini are firmly convinced that no digital revolution can exist without the technical know-how accrued in our 50-years-long experience. Our Customer Service 4.0 is all about this: an extraordinary integration between technical expertise and the availability of data supplied by digital solutions”.
In fact, the availability of data and the expertise of Fabio Perini’s technicians will allow to supply a real Digital Audit and remotely detect causes, establishing in advance actions to solve issues. In this framework, even the Wearable Glasses find their place: in its new “goggle” version, this technologic solution for remote, real-time technical assistance is more ergonomic and performing, with 3D interaction and Augmented Reality. For this device, too, the expertise of Fabio Perini’s technicians is a key factor.
The new platform of services and technical solutions that optimizes production efficiency, reduces operating costs and helps customers maintain the value of their production assets over time.
Fabio Perini chooses MIAC for the worldwide launch of digital solutions for Customer Service and the improvement of production efficiency, consolidating its role as a 360° business partner through the new dimensions of Industry 4.0.
If initially the Digital Tissue™ was aimed only for new installations, today, a few months after its launch, the most important innovation is that the suite of digital solutions can also be implemented for the installed base not only of all Fabio Perini customers but also of machinery from other manufacturers.
In this way, Customer Service becomes 4.0 where the use and analysis of production data, combined with the technical expertise of Fabio Perini's staff, allows customers to maintain the value of their capital assets over time and optimize the Overall Equipment Effectiveness (OEE) of the lines.
Here are the solutions presented in detail:
Tissue Data Cloud
The data processing through different performance indicators gives immediate visibility to the customer of the critical points of the process. Through the use of a Web Dashboard, directly accessible from the Customer Service Portal of Fabio Perini, the data of the line are processed simply and intuitively. Thanks to the analysis of these values and the competence of the Company's technicians, it is possible to offer to customers a real Digital Audit that will allow, even remotely, to detect the causes of line malfunction and establish in advance the actions to solve them.
Two years after the launch of WEAREABLE - the technological solution for remote and real-time technical assistance - the MIAC 2018 becomes the stage for the worldwide launch of the new WEAREABLE GLASSES which becomes more ergonomic in the new "glasses" version and more performing (with the interaction of 3D and AR augmented reality).
Process control is a package of solutions and services that can now be installed not only on all new converting lines but also on an installed base already in production. Being able to measure the tissue web and the finished product and collect the data to transform it into useful information for production efficiency is now part of the complete Digital Tissue™ solution package launched last June at iT's Tissue 2018; a huge advantage for customers who will benefit from this solution to increase production performance, finished product quality and converting process management.
The digital services offered are not only limited to Fabio Perini lines and systems but can also be used on machines of other manufacturers. Thanks to Körber Digital, the new Business Area of the Körber group dedicated to the development of digital solutions, it has been developed a new solution to collect data from any installed base.
In the Open House set up at the Fabio Perini plants in Lucca, it is possible to see the MYTIME line in operation with the patented "Punzoncini" technology for the production of an extremely soft kitchen towel product. Besides, the line is equipped with new upgrades of machinery (T.I.P. - Technical Improvement Program) that allow both the increase in production efficiency and the reduction of operating costs. In particular, a new fire-fighting system has been developed based on two fundamental elements: a guarantee of detection that minimizes false alarms (without the use of optical sensors, UV, IR, ultrasound that would suffer dust, areosol and movements of hot air masses) and a patented extinguishing system based on low-pressure "water mist" technology.
In addition, there are further T.I.P. such as the new glue filter and glue mixer, the reversible rotor to ensure a higher quality of log cutting and blade life up to 30% more and the new lotion applicator "Leonardo" able to deposit 99.9% of the lotion used on paper.