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%.
Toscotec will provide a complete plant with two AHEAD-2.0L tissue machines on a full turnkey basis to Sofidel America’s integrated plant (paper mill and converting) in Inola, Oklahoma, the second greenfield investment of the Group in the United States. The start-up is scheduled for the last quarter of 2019 for PM1 and for the first quarter of 2020 for PM2.
The supply includes two AHEAD-2.0L tissue machines, equipped with second generation TT SYD and gas-fired TT Milltech-DYH Duosystem Hoods, with a high level of energy recovery. Each AHEAD-2.0L machine features a sheet trim of 5,500 mm, an operating speed of 2,000 m/min and is designed for an annual production capacity of over 80,000 tons.
The supply also comprises the stock preparation equipment and accessories, Toscotec’s TT SAF (Short Approach Flow) ensuring increased operation efficiency, the Distribution Control System (DCS) and Quality Control System (QCS) and the dust and mist removal systems.
The project’s turnkey scope includes 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 system (Fresh Water Treatment Plant and Waste Water Treatment Plant).
Toscotec will also provide the detailed mill engineering according to US codes and standards, the construction management, the plant and the machine erection, commissioning and start-up supervision and training programs.
The two tissue lines are dedicated to the production of toilet paper and towels and will process 100% pre-dried virgin pulp.
Luigi Lazzareschi, CEO of Sofidel, states: "Toscotec’s tissue lines represent an important part of our expansion plan in the US, one of the most important markets for our Group. A key technology investment for our new, integrated plant in Inola to serve the South-Central and Central-Western United States. We opted for one of the most advanced and energy-efficient technology, to help pursuing our penetration in the American market and sustaining the high quality of our products."
The construction of the plant – that will combine sustainability and technological innovation – started in March 2018 and will be completed by mid-2020. Once fully operational, the new facility will employ 300 full-time workers. Since the beginning of the expansion to the United States in 2012, Sofidel has now operations in seven states: Florida, Mississippi, Nevada, Ohio, Oklahoma, Pennsylvania and Wisconsin.
Sofidel is a family-run company owned by Stefani and Lazzareschi families, and is the second biggest player in Europe today, and the sixth worldwide in tissue paper manufacturing, with net sales of 1,947 million USD (2017) and a production capacity of over one million tonnes per year (1,098,000 tonnes in 2017).
"We are honoured to have been selected for such an important investment by Sofidel. And even more so, this project represents the joint effort of two Lucca-based Italian companies who set out to succeed in the USA. I know that we have already achieved important synergies and I firmly believe that working together for a shared expansion target will lead to a successful outcome," says Alessandro Mennucci, CEO of Toscotec.
The Sofidel Group
The Sofidel Group is one of the leading manufacturer of paper for hygienic and domestic use worldwide. Established in 1966, the Group has subsidiaries in 13 countries – Italy, Spain, the UK, France, Belgium, Germany, Sweden, Poland, Hungary, Greece, Romania, Turkey and the USA - with more than 6,000 employees, net sales of 1,724 million Euros (2017) / 1,947 million USD (2017) and a production capacity of over one million tonnes per year (1,098,000 tonnes in 2017). “Regina”, its most well-known brand, is present on almost all the reference markets. Other brands include: Softis, Le Trèfle, Sopalin, Nouvelle, Thirst Pockets, KittenSoft, Nalys, Cosynel, Yumy, Soft & Easy, Volare, Onda, Lycke, Forest, 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 promoting socially and environmentally responsible development.
Sofidel America is a subsidiary of the Sofidel Group. It was established in 2012 through the acquisition of the Cellynne tissue company which was founded in 1988 with two converting plants in Green Bay (Wisconsin) and Henderson (Nevada), and one integrated plant in Haines City (Florida). The company is now active in seven states – the original three already listed, as well as Oklahoma (Tulsa), Mississippi (Hattiesburg), Ohio (Circleville) and Pennsylvania (Philadelphia) where the company has its American headquarters. Furthermore, a new integrated plant is currently under construction in Oklahoma (Inola).
Nettingsdorfer Papierfabrik AG & Co KG selected Toscotec to rebuild the dryer section of PM6 at Nettingsdorf mill in Austria. Nettingsdorfer Papierfabrik is a member of Smurfit Kappa Group and one of the largest European sites of the company. The mill is one of the leading producer of containerboard in Europe. The paper machine 6 produces Kraftliner with 7.4 m reel trim and 1100 mpm speed.
The rebuild of the dryer section of PM6 is part of the Future Energy Plant Project. This forward-looking project has the objective to reduce CO2 emissions by 40,000 tonnes (= 2/3 of the current emissions).
With this rebuild, Toscotec breaks new ground and takes it to the next level, by supplying a new dryer section for a large-format paper machine.
Smurfit Kappa has decided to install 5 TT SteelDryers (3 additional and out of the 63 existing dryers 2 will be replaced), as the best technical solution to achieve its production and efficiency increase targets. The TT SteelDryers will be designed for a steam pressure of 12 barg. The supply is on a turnkey basis, including erection supervision, commissioning and start-up assistance.
The rebuild is scheduled for the second quarter of 2019.
About Smurfit Kappa Group
Smurfit Kappa is one of the leading providers of paper-based packaging solutions in the world, with around 46,000 employees in approximately 370 production sites across 35 countries and with revenue of €8.6 billion in 2017. SK is located in 22 countries in Europe and 13 in the Americas and is the only large-scale pan-regional player in Latin America.
For further information, please contact:
Enrico Fazio, Head of Sales, Toscotec Paper & Board division, firstname.lastname@example.org
Toscotec signed an agency agreement for both its Tissue and Paper & Board divisions with Chemitex Egypt for Trading & Agencies, S.A.E. to increase its sales in the Egyptian market, where it recently landed a number of P&B rebuilding orders.
Toscotec entrusted Sameh Habib, founder and owner of Chemitex-Egypt, with the agency. Habib has fifteen years of sales experience in the tissue and paper industries in Egypt.
Following the deal with Toscotec, Habib said, “The Egyptian paper and tissue market has a high growth potential. Toscotec’s technology fits very well in this market for its strong focus on customization and flexibility, paired with energy reduction.Building on our customer portfolio and the relationships of mutual respect, trust, and cooperation we established, we expect to see promising results in the coming years”.
S.TO.R.I., owned by the Toscotec Group, specializes in maintenance services for all minor and major rolls used in papermaking and converting machinery of the tissue and paper industry. In 2017, S.TO.R.I. set a record for turnover in its forty-five year history. This positive performance derives from the strategic synergies achieved with Toscotec, who acquired 100% of S.TO.R.I.’s shares in December 2011. In the period from 2012 to 2017, S.TO.R.I. sustained a 30% growth rate and interim results in 2018 have been confirming this trend, leading to expectations that it will outperform last year’s achievements.
Since 2012, S.TO.R.I. and Toscotec have deepened their long-standing cooperation. By merging S.TO.R.I.’s specialization in rolls maintenance with Toscotec’s engineering capabilities, they accomplished full integration of expertise and higher efficiency in the design and services of roll refurbishing. S.TO.R.I.’s workshop and offices are located inside Toscotec’s headquarters, in Marlia (Lucca).
S.TO.R.I.’s professional experience was built over forty-six years, starting from its foundation in 1972, when it started providing maintenance for papermaking and converting machines. S.TO.R.I. focuses on the inspection, repair and overhaul of not only press rolls but all other rolls, such as forming roll, wire and felt rolls, pope reel drum, and spools. Its mission is to deliver highly specialized services on a continuous basis. The timing becomes important insomuch as customers aim to increase their OEE and reduce maintenance costs.
S.TO.R.I.’s specialists make a precise assessment of the wear conditions of a roll and evaluate its expected performance and risk of failure, so that overhauling can be scheduled efficiently, maximising operation life and minimizing maintenance costs. The majority of S.TO.R.I.’s customers nowadays rely on predictive maintenance. Through regular vibration analyses, S.TO.R.I. estimates the performance trend of a given roll and the possibility of failure. Based on these results, it predicts the period before the next maintenance. This assessment is always a balance of different factors. Drawing on their vast experience, S.TO.R.I.’s specialists can provide the customer with a number of solutions, factoring in time, quality and cost. Based on the contingent needs of the mill, they apply the best-customized solution at a given moment in time. As a result, S.TO.R.I.’s skilled technicians know the components inside out, including their history, weak points and features, much like a doctor knows his patients.
S.TO.R.I.’s range of highly specialized services include predictive maintenance, preventive maintenance, press roll revision and complete overhauling, dynamic balancing, upgrades and non-destructive examinations (NDE). For press roll overhauling, for instance, the company provides complete service packages, including inspection, repairs and spare parts.
Production capacity exceeds 450 components per year, of which suction press rolls and blind drilled press rolls account for approximately 40%, while the rest is made up of various rolls of tissue, paper and converting machines.
S.TO.R.I.’s client base is twofold. Toscotec-associated business accounts for approximately 20% of turnover and covers Europe, Africa, the Middle East, South America and South-East Asia. Italy-based paper mills and converting companies generate approximately 80% of turnover. Essity, Smurfit Kappa, Lucart, Sofidel, Wepa, Cartiere Carrara, Industrie Cartarie Tronchetti, Industrie Cartarie Pieretti, DS Smith, Renova, The Navigator Company are among its main customers. To this second client base, Stori provides maintenance for equipment supplied by any manufacturer. As a result, S.TO.R.I.’s expertise and experience encompasses a wide range of technical solutions designed throughout the years by all the main suppliers and it equips S.TO.R.I.’s experts with the ability to devise tailor-made upgrades for its customers.
Toscotec has revealed plans to expand its tissue and paper & board businesses in Brazil. Toscotec announced that Ricardo Domingues has joined the group as Sales Manager of the Brazilian market, both for tissue and paper & board.
Toscotec is set to consolidate its market position with the support of Domingues, who brings over 20 years of experience in the tissue and paper industry in Brazil.
Thanks to Domingues’ international expertise in design, sales and services, Toscotec is taking a new step in growing its customer base in Brazil.
On July 27, Hygienic Tissue Mills started up a Toscotec-supplied TT WIND-P tissue rewinder at its Pietermaritzburg mill, in eastern South Africa. This is a repeated order for Toscotec, following the supply of a MODULO-PLUS tissue machine, PM2, in 2017. The TT WIND-P slitter rewinder serves PM2, processing 100% virgin pulp and recycled paper parent rolls.
The TT WIND-P slitter rewinder features 2 unwind stands and handles parent rolls of 2750 mm sheet trim and 2500 mm diameter, with a design speed of 1500 mpm. The pneumatically loaded slitting system has a minimum width of 150 mm. Toscotec supplied the complete electrification and control system, and the sectional drive system. The scope of supply also included the erection supervision, commissioning, start-up assistance, and on-site training.
Toscotec Start-up & Service Engineer David Ponte commented, “It was one of the fastest commissioning I have seen for a rewinder. The TT WIND reached its maximum speed in record time with a final product that was already sellable. Thanks to the great cooperation of Hygienic Tissue’s team, we completed fine tuning in two days with the machine running at top speed”.
Hygienic Tissue CEO Ashraf Jooma said, “On the day of start-up, we reached the maximum speed in a few hours. On this rewinder, we expect to get the same efficiency that we have on the MODULO-PLUS machine. High efficiency and consumption reduction are our priorities, and we are happy with the results we are getting in both areas”.
Matteo Giorgio Marrano, Toscotec Area Sales Manager said: “the TT WIND-P rewinder completed the scope of supply of a MODULO-PLUS tissue line that has been running efficiently for nearly one year and a half. This is a new achievement for Toscotec in the South African market, which has been growing steadily in the last few years. Hygienic Tissue’s strong focus on energy savings matches our mission of tailoring the design of high performing tissue machines to the mill’s specific working conditions, in order to optimize energy usage. The good performance of the slitter rewinder goes into this direction”.
Toscotec North America, Inc. Green Bay, WI and Toscotec S.p.A. Lucca, Italy announced that John Holton has joined the group as Technical Support and Service Coordinator for North America.
Holton comes to Toscotec with over 30 years of Tissue Industry experience and will assist Toscotec’s growing customer base in North America.
Holton is a 30 Year TAPPI Member active at the Committee Level and past presenter and contributor to Tissue World Exhibitions in both the US and Europe.
Toscotec will supply a new MODULO-PLUS tissue line to Celupaper S.A. of the leading South American group Grupo Vual, based in Argentina. The MODULO-PLUS machine - PM5 - is scheduled for delivery in autumn 2019 and it will be installed at Papelera Nicaragua mill.
The MODULO-PLUS has a daily production of 65 tpd and is equipped with TT SuctionPressRoll, TT SYD-3200MM and TT Milltech-MGYH Multigen hoods. The scope of supply also includes the approach flow system, the steam and condensate system and the machine and distribution control system.
PM5 is the fourth repeated order awarded by Celupaper to Toscotec in 4 years. The Italian manufacturer had previously supplied a major rebuild on PM2 in 2015, then a MODULO machine - PM3 - in 2016 and finally PM4, a MODULO-PLUS line, which started up in mid-July 2018.
Toscotec’s Area Sales Manager Gabriele Romanini said, “The fact that Celupaper chose to work again with us on their PM5 project is an exciting challenge to exceed their expectations on productivity and energy reduction. Our TT DOES (Drying Optimization for Energy Saving) package, in combination with our Multigen Hood in cogeneration mode, is the core of this effort. We are currently working on the engineering, where the design of our system will integrate into the mill’s cogeneration plant with a gas turbine. Back in 2011, our Energy and Environment department won the PPI Efficiency Improvements of the Year Award with the Spanish producer L.C. Paper 1881 SA, for the effective integration of the tissue machine’s hood system with the cogeneration facility. Drawing on that experience, we expect to achieve substantial energy recovery and very interesting cuts on the machine operating costs”.
Mario Speranza, CEO of Celupaper S.A. commented on the order, “We invest in leading-edge technology to step up our growth in the high-quality tissue market in South America. Toscotec’s tailor-made design has once again provided us with the flexibility and competitive advantage we need to succeed. We knew that Toscotec had significant experience with cogeneration plants and therefore we have great expectations for the performance and consumption of PM5”.
Cascades Packaging selected Toscotec for the supply of TTSteelDryers to be installed at its Cabano mill in Canada. This is a repeated order, following a previous order by Cascades Packaging for a major dryer section rebuild at Kingsey Falls mill. Cascades Packaging confirmed its trust in Toscotec, as the right partner to achieve its strategic objectives of paper machine optimization.
On this project, Toscotec will supply seven TTSteelDryers for the first dryer section, specifically designed for an operating steam pressure of up to 11 barg. The new steel drying cylinders will allow a boost of production and an increase in sheet width at the beginning of the dryer section. Thanks to their reduced shell thickness, TTSteelDryers feature a higher heat transfer rate, compared with cast iron dryers. Since the thermal conductivity of steel and cast iron is similar in the range of operating temperatures, steel dryers with thinner shells offer a higher drying capacity. The scope of supply also includes erection supervision, commissioning and start-up assistance.
Toscotec thus further strengthens its partnership with the Cascades Group in North America. With this new reference, the Italian supplier also reinforces its leadership with respect to the design and upgrade of the dryer section of paper machines.
Delivery is expected for mid-November 2018.
About the Cascades Group
Established in 1964, Cascades produces, converts and markets packaging and tissue products that are composed mainly of recycled fibers. The Company employs 11,000 employees, who work in more than 90 production units located in North America and Europe. With its management philosophy, half a century of experience in recycling, and continuous efforts in research and development as driving forces, Cascades continues to deliver the innovative products that customers have come to rely on.