Advanced digital services help increase overall mill productivity through expert insights and analysis of mill data that improve business decisions
ABB recently added ABB AbilityTM Collaborative Operations to its service deliverables at a major paper mill in East Java, Indonesia. The site produces a variety of printing and writing paper, other paper-related products, and packaging products including cardboard boxes. With an annual capacity of 320,000 metric tons, the mill is one of the world’s largest single-site producers of writing stationery.
Automating production requires processing large amounts of data. As complexity increases, so does the volume of data. Collaborative Operations helps paper producers to make productive use of this data to identify and address production, quality and cost issues that can inhibit peak performance. This improves return on capital. Collaborative Operations helps to maximize business value by turning data insights into direct action.
At the mill, Collaborative Operations is reducing cycle times on product grade changes, resulting in higher production. It is also stabilizing moisture and other additive levels using multivariable predictive controls. Specific improvements include increased production due to higher equipment availability, fewer sheet breaks, lower chemical costs and reduced paper quality variation. These improvements all lead to better product quality and consistency, fewer rejects and more sales.
This project builds upon ABB’s 15-year history of delivering traditional and advanced services to the mill. Collaborative Operations enhances ABB’s ability to positively impact daily mill operations to ensure that results achieved over the years will continue and improve.
ABB has three Collaborative Operations Centers dedicated to pulp and paper industry customers in Finland, the United States, and now Singapore, as well as many more that serve other industry segments. All three pulp and paper centers may be involved with delivering advanced services to this mill in order to leverage various skill sets in each region.
ABB AbilityTM Collaborative Operations is a true Internet-of-Things application and is part of the company's portfolio of ABB AbilityTM digital solutions. Collaborative Operations provides performance management, remote monitoring and preventive analysis technologies to improve security, efficiency and productivity in various industries. ABB AbilityTM Collaborative Operations Centers connect people in enterprise-wide production facilities and headquarters to ABB’s technology and expertise.
ABB (ABBN: SIX Swiss Ex) is a pioneering technology leader in power grids, electrification products, industrial automation and robotics and motion, serving customers in utilities, industry and transport & infrastructure globally. Continuing a history of innovation spanning more than 130 years, ABB today is writing the future of industrial digitalization with two clear value propositions: bringing electricity from any power plant to any plug and automating industries from natural resources to finished products. As title partner in ABB Formula E, the fully electric international FIA motorsport class, ABB is pushing the boundaries of e-mobility to contribute to a sustainable future. ABB operates in more than 100 countries with about 147,000 employees. www.abb.com
WestRock Company (NYSE: WRK), a leading provider of differentiated paper and packaging solutions, today provided updated information on the impact of Hurricane Michael on its containerboard and pulp mill located in Panama City, Florida.
The Panama City area has been substantially impacted by Hurricane Michael, and the priority remains the safety and health of our employees and their families. We are pleased to report that all of Panama City mill’s employees have been accounted for and are safe. The Company is working to support our team and the community as recovery continues.
As previously reported, the Company’s mill in Panama City received extensive damage from Hurricane Michael. Due to the extraordinary efforts of employees, contractors, vendors, our insurance carrier and government officials, the Company has already made substantial progress in assessing the damage and implementing required repairs to return the mill to operation.
The Company expects that the linerboard production system will return to full production capacity within 30 days. Market pulp production is expected to begin by the end of November, but will likely be limited to no more than 50% of the mill’s market pulp production capacity for an estimated period of approximately six months. The mill has normal annual production capacity of 353,000 tons of linerboard and 292,000 tons of market pulp.
The total cost to the Company from Hurricane Michael is currently unknown. While the Company maintains property damage and business interruption insurance coverage, there will be a time lag between the initial incurrence of costs and the receipt of insurance proceeds as the Company restores the mill back to normal operations.
The Company will provide an additional update on the status of the mill on its November 5, 2018, earnings conference call.
WestRock (NYSE: WRK) partners with our customers to provide differentiated paper and packaging solutions that help them win in the marketplace. WestRock’s 45,000 team members support customers around the world from more than 300 operating and business locations spanning North America, South America, Europe, Asia and Australia. Learn more at www.westrock.com
The Italy-based company is one of three Italian organisations, along with Intesa Sanpaolo and Gruppo Hera, that are part of the network created by the Foundation
Lucart is increasingly committed to the circular economy. The Italy-based Group, a leading manufacturer in Europe of tissue paper, airlaid products, and MG paper has joined the Ellen MacArthur Foundations CE100 network, a pre-competitive innovation programme established to enable organisations to develop new opportunities and realise their circular economy ambitions faster.
Launched in 2010, the Ellen MacArthur Foundation aims to accelerate the transition to a circular economy. Since its creation, the charity has emerged as a global thought leader, establishing the circular economy on the agenda of decision makers across business, government and academia.
Lucart, which has made of sustainability and innovation in the environmental field its core values, is one of only three Italian organisations that are members of the CE100 along with, Intesa Sanpaolo and Gruppo Hera. The network focusses on collaboration, capacity building, networking and research and insights - bringing together companies to create further opportunities for cooperation and innovation.
“Quality, innovation and sustainability: these are the key words for building the future of tissue paper and of our Group. This is why joining the community created by the Ellen Macarthur Foundation makes us proud of what we have achieved to date: it demonstrates our full commitment to a “circular” paper economy, as we like to call it” – Massimo Pasquini, Chief Executive Officer of Lucart, commented – “We hope that this cooperation will pave the way for new, challenging scenarios for the development of circular economy on a global level, covering a multitude of different sectors and projects. And we want to play an active role in this development”.
In the environmental field, Lucart is a pioneering company in Europe: in 1997, it launched the world’s first recycled toilet paper with Mater-Bi packs on the market, and in 1998 it was the first company in Italy to obtain the Ecolabel. In 2010, the company launched the Natural project in cooperation with Tetra Pak®, creating Fiberpack®, a virtuous and award-winning circular economy project, which represents the evolution of paper. Thanks to this project, the Group has managed to recycle more than 3.6 billion beverage cartons, which, if lined up one after the other, would cover a distance equal to the circumvention of the Earth 21 times over and, above all, to prevent the emission of 93,800 tonnes of CO2e into the atmosphere, which is equal to the emissions of as many as 736,000 trips by car from Rome to Milan.
Lucart, a leading company in Europe in the production of tissue paper products (paper items for daily use such as toilet paper, kitchen paper, napkins, tablecloths, handkerchiefs etc.), airlaid products and MG paper, was founded in 1953 by the Pasquini Family. The company's production activities are distributed over 3 Business Units (Business to Business, Away from Home and Consumer) operating in the development and sales of products with brands such as Tenderly, Tutto, Grazie Natural and Smile (Consumer area), Lucart Professional, Tenderly Professional, Fato and Velo (Away from Home area).
Lucart's production capacity exceeds 395,000 tonnes/year of paper on 12 continuous machines and 65 converting lines. Its consolidated turnover amounts to more than €450 million, with more than 1,500 employees in ten production plants (five in Italy, one in France, one in Hungary and three in Spain).
Paper & Beyond, the new event concept where circular bioeconomy leaders meet, took place just a week following the release of the EU’s new Bioeconomy Strategy, which set out a clear path for better linking the bioeconomy and circularity.
“The new European strategy comes at a defining moment for the bioeconomy” says Karl-Henrik Sundström, CEO of Stora Enso and Chairman of CEPI. “Industry’s transformation is gaining pace across the entire forest fibre and paper value chain. As the mainstream renewable and recyclable material industry, we are ready to take the lead on Europe’s circular bioeconomy”.
The first of its kind conference got off to an innovative start with a competition gathering some of Europe’s most promising young researchers. From the engineering of spider silk strong nanocellulose filaments to paper-based electrodes for fuel cells, researchers illustrated the innovativeness and European lead in forest fibre research.
Building on this year’s theme, the “Europe & Beyond – Getting the best from the bioeconomy” session welcomed keynote speaker Peggy Liu, a world-renowned sustainability expert on China who brought a global perspective on the circular bioeconomy. She touched upon recent developments in China, including the country’s waste restrictions, its policy on single-use plastics and its recent investments in Europe under the Belt and Road initiative.
Following the positive trends in production (up 1.5%), exports (up 5.4%) and investment (up 7.5%) seen in the latest market data for 2017, RISI returned to provide insights into circular bioeconomy markets, with, for the first time, a business intelligence session on European nanocellulose markets.
Paper & Beyond also hosted the final conference of the EU-funded Provides project which has confirmed the Deep Eutectic Solvents (DES) technology. This breakthrough aims at achieving a 40% reduction in energy use and a 80% life cycle reduction in CO2 emissions, while also producing high-quality lignin from wood for biochemicals or biocomposite production. The consortium will continue research on a DES pulping pilot and demo, aiming at commercial deployment by 2030.
CEPI is the European association representing the forest fibre and paper industry. Through its 18 national associations CEPI gathers 495 companies operating more than 900 pulp and paper mills across Europe producing paper, cardboard, pulp and other bio-based products. CEPI represents 22% of world production, €82 billion of annual turnover to the European economy and directly employs more than 177,000 people.
From forest fibre technology to advance paper design, the industry currently invests almost 5.5 billion annually in Europe and is a recognised leader of the low-carbon circular bioeconomy transition. CEPI’s 2050 ‘Investment Roadmap’ outlines the industry’s vision to advance this transformation in Europe through value creation and decarbonisation.
Toscotec announced that it has been awarded a landmark contract by the Marutomi Group to supply two MODULO-PLUS ES tissue lines. The machines will be installed at Marutomi Paper’s mill and at Ono Paper’s mill in Fuji city, Shizuoka, Japan, and are scheduled for start-up respectively in the first and second half of 2019. This is a repeated order for Toscotec, who supplied a Steel Yankee Dryer TT SYD-12FT to Marutomi Paper in 2013, to replace an old cast iron Yankee.
Toscotec will provide two MODULO-PLUS ES (Energy Saving) tissue machines, featuring a second generation Steel Yankee Dryer TT SYD, steam-heated hoods TT Milltech-DYH, and the shoe press TT NextPress. Each of the MODULO-PLUS ES machines has a sheet width of 2,850 mm, an operating speed of 1,500 m/min, and an annual production of over 22,000 tons.
The scope is the same for both machines and comprises Toscotec’s patented TT SAF (Short Approach Flow) system, a pope reel automatic shaft return system, an in-line shaft puller and the tissue machine’s dust and mist removal systems. Toscotec will supply its proprietary Distributed Control System TT DCS, which was developed specifically for these projects on a Mitsubishi platform, in cooperation with the Japanese Corporation. The production lines’ detailed engineering, erection supervision, commissioning and start-up assistance complete the supply.
Mr. Takeo Sano, President of Marutomi Paper Co., Ltd., says, “We have been running a TT SYD for four years now and are very impressed with its performance. We immediately thought of Toscotec when we approved this new major investment project. Over the past few years we got to know the company, its people and services and we trusted in their technical expertise and vast experience. We have very high expectations in terms of both product quality and energy efficiency”.
“With this new order of two complete tissue production lines, we aim to strengthen our cooperation with the Marutomi Group and become a strategic partner for their expansion. We married the same philosophy of resource and environmental protection and I believe that they will be satisfied with the energy saving results of our MODULO-PLUS ES line. In recent years, we supplied three TT SYD to Japan and we are happy to get such a positive feedback from this demanding market” comments Alessandro Mennucci, CEO of Toscotec.
The supply of these two important projects is being supported by Kobayashi Engineering Works, Ltd.
About Marutomi Paper Co., Ltd. and Ono Paper Co., Ltd.
Founded in 1955, Marutomi Paper is one of the main tissue producers in Japan, and acquired Ono Paper in 2006. The Marutomi Group today mainly specializes in toilet tissue from 100% recycled fiber, with an annual production output of 150,000 tons, of which 95% of toilet tissue and 5% of kitchen towel, and an estimated market share of 15%.
International technology group ANDRITZ has just announced the successful closing of its previously announced acquisition of Xerium Technologies, Inc.
Xerium, headquartered in Youngsville, North Carolina, is a global manufacturer and supplier of machine clothing (forming fabrics, press felts, drying fabrics) and roll covers for paper, tissue, and board machines, including maintenance and aftermarket services. With its Smart® technology, the company provides a sophisticated digital software tool to optimize pressing performance by means of sensors integrated into the roll covers.
ANDRITZ, headquartered in Graz, Austria, is a globally leading supplier of plants, equipment, and services for hydropower stations, the pulp and paper industry, the metal working and steel industries, and for solid/liquid separation in the municipal and industrial segments.
ANDRITZ is a globally leading supplier of plants, equipment, and services for hydropower stations, the pulp and paper industry, the metal working and steel industries, and for solid/liquid separation in the municipal and industrial segments. Other important fields of business are animal feed and biomass pelleting, as well as automation, where ANDRITZ offers a wide range of innovative products and services in the IIoT (Industrial Internet of Things) sector under the brand name of Metris. In addition, the international technology Group is active in power generation (steam boiler plants, biomass power plants, recovery boilers, and gasification plants) and environmental technology (flue gas cleaning plants) and offers equipment for the production of nonwovens, dissolving pulp, and panelboard, as well as recycling plants.
A passion for innovative technology, absolute customer focus, reliability, and integrity are the central values to which ANDRITZ commits. The listed Group is headquartered in Graz, Austria. With over 160 years of experience, circa 30,000 employees, and around 280 locations in over 40 countries worldwide, ANDRITZ is a reliable and competent partner and helps its customers to achieve their corporate and sustainability goals.
Portuguese Producer chooses A.Celli Paper for its new investment
It is with extreme satisfaction that A.Celli Paper S.p.A. announces the start of a precious collaboration with Fapajal – Fábrica De Papel Do Tojal, S.A. through the agreement for the supply of a latest-generation E-WIND® T80S rewinder for the production of tissue.
A.Celli Paper E-WIND® T80S is a modular and fully automated rewinder, running at 1000mpm, with built-in electrical cabinets, capable of managing products that involve a specific volume, diameter and cutting format while also guaranteeing extra capacity during production peaks.
It is customisable, plug-and-play, perfectly adaptable and compatible with any standard rewinding system or complete line in the tissue sector.
Yet another confirmation for A.Celli Paper technology that is even more present and is capable of meeting the needs of different customers, promptly answering the motley production variables with flexibility.
Fapajal has a paper-making tradition dating back to 1755 and is currently focussed on producing tissue paper. Headquartered in São Julião do Tojal, Loures, the Company relies on the contribution of over 150 employees and approximately 50 outsourced employees.
At a special conference just organised as part of the Paper and Beyond 2018 event in Brussels, the first phase of the PROVIDES project was officially completed. PROVIDES, which stands for ‘PROcesses for Value added fibres by Innovative Deep Eutectic Solvents’, is a research and innovation project within the Biobased Industries Initiative, with the goal of significantly reducing CO2 emissions in pulp and papermaking.
Sappi is an active participant in the project, thus supporting the pulp and paper industry’s technological transition towards meeting its climate objectives.
The completion of the first phase was celebrated with the publication of a booklet describing the potential of Deep Eutectic Solvents (DESs) for creating breakthrough innovations in the pulp and paper industry. The publication ‘Deep Eutectic Solvents in the paper industry’ can be downloaded here.
Revolutionising the industry
In November 2011, the Confederation of European Paper Industries (CEPI) launched its vision for the sector in the next 35 years, concluding that breakthrough technologies would be needed to make the industry more sustainable. Specifically, it aims to achieve an 80% reduction of CO2 emissions and at the same time create 50% more value. The PROVIDES consortium shows that a revolutionary change is now possible. New, mild pulping technologies based on natural Deep Eutectic Solvents lead to a significantly more sustainable process that is energy-, cost- and resource-effective, while producing much lower CO2 emissions.
The total DES concept
Deep Eutectic Solvents are nature-based, renewable, biodegradable, low-volatile and cost-effective. The overall objective of the DES concept is to achieve a 40% reduction of energy use and an 80% reduction of CO2 emissions in pulp and papermaking. The DES concept will enable the industry to obtain a radically new, sustainable and techno-economically feasible pulping technology, while also enabling the selective recovery of dissolved components. In addition, DESs can be regenerated and recycled, ensuring economical use of resources. This technological innovation produces high-quality cellulose fibres for papermaking, while simultaneously producing high-quality lignin and hemicellulose fractions for a variety of high-volume applications.
Results and achievements
In the first phase of the PROVIDES project, more than one hundred new DESs were developed. Of these, two have been further developed as successful delignifying agents. The project proved that the entire DES pulping process can be run at operational costs similar to those kraft pulping, and that the resulting cellulose fibres have good tensile strength and extreme internal bond strength. In addition, it was proven that DES delignification results in 95% lignin removal, and that the lignin can be successfully recovered and the DES regenerated.
In the coming years, the pulping part of the DES research cluster, coordinated by the Institute for Sustainable Process Technology (ISPT), will continue to conduct further applied research towards the realisation of a DES pulping pilot and demo, ultimately leading to commercial implementation in 2030.
As every year, emtec Electronic will attend the ABTCP in Sao Paulo, Brazil. The exhibition takes place from October 23rd to 25th. The German producer of innovative lab and online testing equipment can be found at booth no. 137/138 together with its Brazilian representative Elof Hansson.
Emtec will present the state-of-the-art charge measuring systems CAS touch! and FPA touch! Both devices are used to optimize the wet-end process, by measuring the interaction between particles or fibers with additives and process chemicals in the pulp suspension. The use of both instruments in the production process helps to optimize the utilization of chemicals with the target to stabilize the process, to improve the product quality and to reduce costs. Another device that can be used in the wet-end of the tissue and paper production is the DFA – Dynamic Filtration Analyzer, which helps to determine the influence of chemicals on drainage and retention behavior.
But, also producers of base and final products will find innovative measurement equipment at the booth: the well-known TSA – Tissue Softness Analyzer which is used to reliably assess the Softness, Smoothness/Roughness and Stiffness as well as the overall Hand Feel of tissue and nonwoven materials. Additionally, the EST – Surface & Sizing Tester is shown. The EST is a useful tool to determine important paper surface properties such as surface hydrophobia / sizing as well as the surface porosity, which influence printability, coatability and gluability of paper and board.
Designed specifically for HP Indigo digital presses, the new imPress™ ID chemistries are up to eight times more efficient at generating print adhesion
Solenis, a leading global producer of specialty chemicals, has introduced a new line of imPress™ ID paper additives designed exclusively for HP Indigo digital presses. The new imPress™ ID chemistries are up to eight times more efficient at generating Indigo print adhesion. With these new additives, paper mills can efficiently and cost-effectively produce papers with a three-star rating for HP Indigo digital presses.
“As digital printing continues to take market share from offset presses, the demand for papers optimized for digital printing systems will increase,” said Tom Hayden, Global Marketing Director, Printing and Writing. “Our imPress™ ID additives are very easy to run, so papermakers can diversify by quickly adding Indigo-approved grades to their portfolios. Mills that already produce Indigo grades can enjoy a number of additional benefits.”
A main benefit is improved runnability. With imPress™ ID paper additives, no changes are required to the size press or machine settings. The chemistry is non-charged, so it doesn’t form deposits, agglomerate or cause stickies-related issues. In addition, the new imPress™ ID products are exceptionally versatile and work well with optical brightening agents and other size press chemistries.
“Our researchers spent a great deal of time refining this product,” said Dan Varnell, Solenis Research Fellow. “The result is an innovative chemistry that dramatically increases the performance of the paper printed on Indigo presses."
In the past, polyethyleneimine (PEI) or poly(ethylene/acrylic acid) was used to promote Indigo image adhesion, but PEI resulted in yellowing issues and P(Et/AA) dispersions required special conditions. The Solenis imPress™ ID technology relies on thermodynamic attraction of the print ink to the paper treatment. Free energy drops as the ink and the treated paper interact with each other, resulting in more efficient adhesion.
Currently, imPress™ ID-115 and ID-120 are available in North America, and imPress™ ID-215 and ID-220 are available in Europe.
For more information about Solenis imPress™ ID paper additives and technology, visit www.solenis.com/imPress.
Solenis is a leading global producer of specialty chemicals for water intensive industries, including the pulp, paper, oil and gas, chemical processing, mining, biorefining, power and municipal markets. The company’s product portfolio includes a broad array of process, functional and water treatment chemistries as well as state-of-the-art monitoring and control systems. These technologies are used by customers to improve operational efficiencies, enhance product quality, protect plant assets and minimize environmental impact. Headquartered in Wilmington, Delaware, the company has 35 manufacturing facilities strategically located around the globe and employs a team of approximately 3,700 professionals in 118 countries across five continents. For additional information about Solenis, please visit solenis.com.