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Tissue winder rebuild: how to reach 300mpm speed increase and bulk losses below 2.5%

Upgrades & Retrofits | Luca Silvestri, 16 June 2020

One of the most labor-intensive and potentially dangerous parts of the tissue and nonwovens production line is the winding system, which makes a winder rebuild an essential part of an overall plant upgrade

Directly connected to the slitting system, the winder requires proper core handling and gluing and perfect winding tension and roll ejection.

Many companies are still operating with older winding systems, which can increase the risk to operator safety and result in an inferior product. However, a rebuild 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

A slitting section upgrade ensures simplification with the automatic positioning of knives and counter-knives. The system also features spreader rollers with variable bow and special carbon shafts that improve acceleration and overall production. In addition, 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 winder 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. In addition, rewinder efficiency is improved, 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. 

A.Celli 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 winding system when they asked us for a rebuild. 

The company was particularly concerned with efficiency, quality of the final product and safety, as it encountered the following problems:

  • Efficiency. Poor efficiency was primarily due to excessive bouncing during winding. 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 specifications of the paper machine built for the customer were:

  • Paper grades: Tissue, from 16 to 40 gsm (9.8 to 24.5 lbs/3,000 ft2)
  • Paper width: 2,900 mm (114’’)
  • Winder design speed: 1,600 m/min (5,250 ft/min)
  • Jumbo roll diameter: 3,000 mm (118”)

A.Celli Paper installed two additional unwind stands, each of which came equipped with automatic tension control. In addition, they:

  • Replaced the jumbo roll handler
  • Upgraded the plant’s existing unwinders to provide them with automatic tension control
  • Upgraded the ABB electrical drive
  • Upgraded the relieving system
  • Installed new safety fences
  • Conducted a 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 winder rebuild

The results aachieved were significant. A.Celli’s customer obtained an increase in speed of 200 mpm immediately after the 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!

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