[UPDATED ON FEBRUARY 2023]
One of the most labor-intensive and potentially dangerous parts of the tissue production line is the winding and rewinding system, making rewinder machine rebuilds an essential part of an overall plant upgrade.
Directly connected to the slitting system, the rewinder requires proper core handling and gluing and perfect winding tension and roll ejection.
Many companies are still operating with older systems, which can increase the risk to operator safety and result in an inferior product. However, a rebuild of the tissue rewinder can change all that, providing companies with a safe and highly productive solution capable of producing the highest quality rolls.
What a tissue and paper rewinder rebuild looks like
There are several key components that can be upgraded. Whether a company chooses to upgrade individual components or do a full winder rebuild will depend on their specific needs.
1. Slitting group
The upgrade of the slitting section with an automatic system for the positioning of knives and counter knives leads to greater simplification. The system also features spreader rollers with variable bow and special carbon shafts that improve acceleration and overall production. Finally, everything is managed with the use of proprietary software via a user-friendly dashboard.
2. Core loading and roll ejector system
When it comes to core handling and gluing, the new system is fully automated to simplify these processes. It can be installed on an existing system, with the benefit of reduced operator tasks, reduced doffing cycle time and improved efficiency of the rewinder. Best of all, the operator does not need to be near the machine during operation or enter the machine itself to set up the cores.
3. Tissue unwinder web tension
This upgrade involves the addition of a second motorized roller to work in tandem with the first. The lower of the two motorized rollers rests on a load cell, which is capable of constantly detecting variations in web tension. Information is sent from the load cell to dedicated software that makes automatic adjustments to the motors’ speed to maintain optimal web tension. In addition, it is possible to keep a record of the adjustments and optimize the settings according to the various operators shifts, ultimately eliminating the need for manual adjustments.
4. Drives
The drive system is updated to improve overall reliability and process control, in order to reduce energy costs and the need for maintenance and to make troubleshooting easier and faster.
5. Rewinder safety
The tissue rewinder rebuild includes the installation of:
- Safety fences
- Interlocking access gates
- Automated detection system of personnel in the safety area
- Detection systems for unexpected hazards
- Cameras
- Upgraded automation system that includes Safety Integrated Controllers
6. Tail gluing
This system fully automates the gluing of the finished reel. It reduces safety risks and minimizes the number of tasks the operator is required to carry out. We also improve the efficiency of the rewinder, as no tape is needed to secure the paper rolls and the operator does not need to be near the machine during operation or enter it to make adjustments.
7. Dust Removal System
A custom dust removal system designed to collect dust from rewinder hoods, unwinder suction boxes and other critical points.
Tissue winder rebuild: the case history
A.Celli Paper’s customer, an international group leader in the tissue and personal hygiene products market, used to work with an outdated rewinding system when they asked us for a rebuild.
The company was particularly concerned with efficiency, quality of the final product and safety. Specifically, they encountered the following problems:
- Efficiency. Poor efficiency was primarily due to excessive bouncing during operation. The goal was to increase operating speed to a maximum of 1,600 mpm.
- Quality. The company had bulk losses in excess and poor quality of reels that were produced at higher speeds. Their ultimate target was to increase the quality of their product from two plies to four plies.
- Safety. The company wanted to optimize drive speed control while ensuring full operator safety.
Based on its needs, A.Celli Paper came up with a solution to address these issues.
The rewinder provided to the customer was capable of processing tissue paper from 16 to 40 gsm wound into Jumbo rolls with a width equal to 2900 mm (114'') and a diameter equal to 3000 mm (118''), all at a design speed of 1600mpm.
A.Celli Paper installed two additional unwind stands, each of which came equipped with automatic tension control. The following interventions were also carried out:
- Replacement of the jumbo roll shaft extractor
- Upgrade of the plant’s existing unwinders to provide them with automatic tension control
- Upgrade of the ABB electrical drive
- Upgrade of the relieving system
- Installation of new safety fences
- Full safety integration
The entire installation and wiring were completed over a period of 13 days. The new system took 10 days to commission, another 2 days to start up and 3 days for fine-tuning. After 3 months a performance test was done to ensure the new system was functioning properly.
Results of the tissue rewinder rebuild
The results aachieved were truly significant. A.Celli’s customer obtained an increase in speed of 200 mpm immediately after the tissue winder rebuild was complete, to then arrive a total speed increase of 300 mpm. At the same time, the company reduced its bulk losses by 2.5% and maintained a consistent quality of finished rolls. In addition, the new integrated safety features and fencing improved operator safety, while optimizing drive speed control.
If you too want to achieve the same results, contact us today for a free consultation!
