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Conventional tissue

The demand of tissue grades is showing a continuous growth worldwide, which calls for new installations, especially in developing countries. Recently many new projects have come up worldwide, and PAPCEL Group is very active in this field thanks to the experience of ABK in the tissue technology, and to the experience of PAPCEL in the supply of complete paper production lines. PAPCEL can thus provide complete tissue turn-key projects, including engineering, stock preparation lines, tissue machine, and auxiliary equipment.
To implement such projects, the PAPCEL Group performs the role of Main Contractor, including complete engineering services, project management and total equipment delivery. In the stock preparation area PAPCEL offers complete lines for virgin and recycled fibers, approach flow systems and broke treatment lines. The tissue machines produced and offered range in width from 2.7 to 5.6 meters, and speeds from 1,000 to 2,200 m/min, for a production capacity from 40 to 250 t/day and finished basis weight from 12 to 45 gsm. The products made in PAPCEL’s tissue machine are covering all the tissue grades: sanitary tissue, napkin, hygienic tissue, handkerchief, toweling grades, facial tissue, as well as medical tissue grades.

Common tissue machine design:

  • Headbox
  • Forming part with Crescent former
  • Press part: single suction press, suction and blind drilled press, Shoe press
  • Yankee cylinder: Ø 3.6 - 5.5 m (cast iron or steel) and high-performance hood
  • Fully automated reel
  • Winder for two to four plies
  • Combining calender with adjustable camber
  • Wrapping machine
Tissue machine concept

All offered tissue machines feature the Crescent former forming section, which enables the manufacture of low basis weights at high speeds with minimum investment costs.

The machines are delivered completely equipped with parts and accessories like central lubrication systems, vacuum systems, steam and condensate systems, Yankee cylinders incl. hoods, QCS and DCS systems, complete MCCs etc. Within the scope of high efficiency hoods, complete ventilation systems and steam and condensate systems are supplied. The hoods are equipped with profiling and edge control and opening system for servicing. Between the creping doctor and the reel, a dust suction system is supplied to exhaust the dust generated by the creping operation. Tissue machines may reach operating speeds up to 2,000 m/min on the Yankee cylinder and design speeds up to 2,200 m/min. Reels are equipped with reel spool magazines. Reel rail extension can be supplied for parking up to 3 finished jumbo reels. The combining winders with slitting sections enable to combine up to 4 tissue plies and are equipped with dust exhaust systems. Wrapping machines for shrink-wrapping finished tissue rolls are also in scope of the supply.

Crescent former machinery specifications
  • Hydraulic headbox with cross profile control by means of micro-screw jacks or dilution water for one or two plies. The headbox consistencies are in the range 0.2 - 0.3 %.
  • Crescent former - stock pressed between the wire and the felt is dewatered by hydraulic pressure induced by the wire tension on the forming roll. The roll of a diameter of 1.500 mm is covered with rubber of 0 - 2 P&J hardness. The forming wire is equipped with all the standard accessories. The wire rolls and the breast roll are also covered with rubber of 0 - 2 P&J hardness. The wire retention is 55 to 60 %.
  • The press part gives a Yankee input dryness of 37 - 42 % depending on its design.The most common press configuration is the single suction press: good dryness and final softness of the tissue web are achieved. The suction press roll diameter ranges from 850 to 1,250 mm, depending on the machine width and speed. The design linear load is 90 - 100 kN/m. A relatively long nip is produce, thanks to the large diameter of the roll and of the rubber cover softness and open area. The solution of double press, with a blind drilled press roll following the suction press, gives better dryness, but will compress more the sheet, marginally compromising the final softness. The diameter of the blind drilled press is 800 to 1,000 mm, and its linear load is of 100 kN/m. The most modern solution is the shoe press, which allows optimum control of softness and dryness. The shoe length is reduced with respect to the design for paper grades, 200 mm, as well as the design linear load, about 200 kN/m, to be able to be supported by the Yankee dryer. The flexible shoe press roll is preceded by a felt-dewatering suction roll.
  • Drying part - the needed drying capacity is given by the Yankee dryer size (diameter) and the high efficiency hood temperature and air velocity. The Yankee diameter ranges from 10 to 18 feet (3,000 to 5,500 mm), depending on the production capacity, and the construction material is steel. Operating pressure is up to 8 bar. The hood air temperature is 130-140 °C for steam heated hoods and up to 550 °C for gas fired hoods. Hot air is blown on to the sheet on the Yankee surface at velocities of maximum 140-150 m/s. The split in drying action between hood and Yankee dryer ranges from 40/60 to 60/40: this will give some control on the quality of the final product, as a higher amount of drying made by the hood will give better softness, with higher energy cost, and vice versa.
  • Reel - the tissue reel can be a simple model, pneumatic, for the low capacity machines, or a fully automated hydraulic model for the more performing machines. Particular emphasis is put in the reeling pressure control, to be able to have a very soft reeling for certain grades, like toweling and super-soft qualities. In this cases a model with linear secondary loading may be used. All reels for machine speeds above 1,200 m/min are equipped with empty spool magazine and loader, whereas for lower speeds this feature is optional. Extension rails with room up to three full jumbo reels can be supplied. The last parking station will be also a weighing station for the jumbo reel, before the same is transferred to the winder.
  • Winder – the tissue winder is a combining winder: up to 4 separate plies of tissue are wound to produce a combined web, to be further converted into several consumer’s products. The winder is thus equipped with multiple unwinders, where the jumbo reel as unwound with tape drives. Before the slitting section, a combining hard calender can be installed, to improve the marriage between the tissue plies, and to control the caliper and the smoothness of the final product. To do so, either a camber system or a variable crown roll will be included in the calender, to optimize the evenness of the load. Gap control mode can also be a feature of the calender, giving absolute caliper control. The slitting operation will produce some amount of dust: therefore the calender is equipped with an efficient dust exhaust system.

  

Basic tissue machine design with Crescent former

Image: With single press roll



Image: With two press rolls



Image: With Shoe press unit




PAPCEL/ABK reference choice within the recent period (2011 - 2014):
  • Braswell PM 1, 120 tpd (Brazil)
  • Braswell PM 2, 120 tpd (Brazil)
  • White Mountain Tissue, 105 tpd (USA)
  • MG Tec PM 1, 85 tpd (Romania)
  • EKA KAGIT PM 1, 90 tpd (Turkey)
  • Mediterranean Tissue PM 1 (Egypt)