How to achieve up to 20% higher tissue production flexibility at lower capital investment costs?

PMP (Paper Machinery Producer) has been supporting one of the leading Asian papermakers - Yuen Foong Yu Corporation for the last 20 years, executing projects both in the tissue and paper field.

author: Maja Mejsner

Industry Insight by:

PMP – Paper Machinery Producer

At present, in the tissue area, Yuen Foong Yu Corporation owns seven PMP Intelli-Tissue® 1600 lines – all are installed in Mainland China: in Beijing, Yangzhou and Dingfung, reaching total capacity of 300 000 t/a. 1st Crescent-Former Intelli-Tissue® machine (2.4 m wide) was launched in 2008 in Beijing, China. Excellent results of this project have encouraged YFY to continue partnership with PMP.
2nd and 3rd (PM#5 and PM#6) 2.8 m wide Crescent-Former Intelli-Tissue® were started-up in 2012 in Yangzhou, China. YFY Management Board found out this start-up as the quickest in YFY’s history! After successful start-ups in Beijing and Yangzhou mills, in spring 2013, PMP has been choosen again to support YFY’s development, this time adding four more tissue making lines.
At the end of March 2013, YFY officially announced a massive expansion plan which included investing over 260 mln US dollars in Taiwanese and Chinese plants. At the same time PMP has been awarded a project for four new complete Crescent-Former Intelli-Tissue® 1600 machines built based on Intelli-Tissue® Integrated Tissue Mill Concept (2 TM’s in one building without a basement, with a common control room and replacement parts base). On 3rd July 2014 (PM#7) and on 28th August 2014 (PM#8) in Yangzhou, China, 4th and 5th machine fully designed and produced by PMP started-up easily. Then, on 8th December 2015 (TM#1) and on 14th January 2016 (TM#2) in Dingfung, China, 6th and 7th machine were successfully brought on stream bringing all involved satisfaction and pride.

Integrated Tissue Mill Concept

To optimize the investment, YFY decided to follow the scenario from 2012 (PM#  and PM#6 Yangzhou project) and clone the same concept for an Integrated Tissue Mill: two tissue machines with rewinders, with a common control room in the same building, as well as a warehouse and converting area. The concept of the Intelli-Tissue® Integrated Tissue Mill was implemented both in Yangzhou mill (PM#7 and PM#8) and in Dingfung mill (TM#1 and TM#2) ensuring staff and space optimization, high production flexibility and a significant operation cost reduction. Comparing to a single machine concept, both projects goals ensured: investment costs reduction (up to 20%); reaching high production flexibility and high runnability level (uptime up to 96%); reduction of the staff needed to operate the machines (4 operators per 2 lines); significant reduction of production costs (2 in 1 concept); optimization of the spare parts base (1 base per 2 lines); optimization of the storage space.

Technology that counts

Recent (2) tissue machines are 2.8 (110 inch) reel trim Crescent-Former type tissue machines with an operating speed of 1,600 mpm (5,250 fpm) and daily capacity of 80 tpd each. Machines are producing virgin fiber-based tissue in the basis weight range at the reel from 13 to 31.3 gsm (8-19.1 lbs/3000 ft2) for conversion into facial tissue, toilet rolls and kitchen towels.

The Yangzhou project (PM#7 and PM#8) was split between YFY and PMP. PMP took care of the stock preparation lines (common system for short and long fibres), stock approach lines, both tissue machines including auxiliary systems like mechanical drives, oil lubrication, steam and condensate, dust control, machine controls and instrumentation, as well as shaft pullers. YFY was responsible for the building, rewinders, QCS & DCS and electrical drives. As for machine configuration each was equipped with: hi-tech Intelli-Jet V® hydraulic headbox, four roll Intelli-Former® Crescent-Former, a single nip Intelli-Press® with large 41 in dia suction press roll for higher bulk, a 16 ft steel Yankee Dryer and steam-heated hood system (as natural gas is not available in mill location) and an Intelli-Reel®. Both machines are almost identical with the exception of the headbox technology that is double layer on PM#8 (and consequently the stock prep and stock approach are more advanced) – to increase production flexibility.

Excellent Results matter

The main technological goals were focused on energy savings, premium quality of the final product and production flexibility. Attractive media consumption levels per ton of paper: steam 2.7 T, water up to 7 m3 and electricity up to 619 kWh. Premium quality of the final product is confirmed by the following figures: MD/CD – 1:1.5 – 1:3, moisture profile: 2σ less than 1%, CD basis weight profile: 2σ cov less than 2%.

Task Management

The project for PM#7 and PM#8 for YFY Yangzhou was launched in April 2013 and both TMs were executed simultaneously up to the pre-erection phase taking advantage of our two facilities: PMPoland (Poland) and PMP IB (China). The entire engineering project as well as crucial systems like hydraulic headboxes, SPRs, YDs and hood systems were designed and made in Europe. Other parts including complete forming section, press section structure and a reel where built in China. Both machines were fully pre-erected at PMP Chinese facility in Changzhou and fully tested. After the factory acceptance test they were sent to the mill. A short distance between the facilities (2 hour drive) allowed easy access to resources in case of emergencies. The PM#7 erection at site started in March 2014. Then two months later the PM#8 foundation was ready. As a result, the TMs were put on stream one after another: PM#7 in July and PM#8 at the end of August last year – four months (from base plates up to paper at reel) for each machine. It is worth mention that the saleable paper was reached right-away after the start-up of both machines. It is important because if case of uneffective start-up, each lost hour generates losses.

 

Executing two TMs at the same time was shortening of the delivery time due to optimized execution cycles.
The machines run smoothly and efficiently and are great tools to produce high quality tissue.

Intelli-Tissue® Integrated Tissue Mill Concept

What benefits YFY got when investing in Intelli-Tissue® Integrated Tissue Mill Concept? Having two TMs under one roof?

Benefit #1: much higher flexibility of production lines. For the product they can play more with production options and reduce the necessity of frequent TM adjustment for grades. As a result, better annual TM efficiency is reached. YFY today can set each machine for a different product. At the same time, the number of staff can be reduced as the machines are identical and smart maintenance solutions are applied. Only 4 operators run both machines.
Benefit #2: YFY saved money on capital investment cost. The building has been optimized and well-arranged with a smaller footprint than two independent machine rooms. In Yangzhou the building is simplified – with no basement – only pits for the fan pump and UTM pulpers which helped to save 20-30% of the civil cost when compared to a building with a basement. Crescent former machines are compact (10% shorter in length) when compared to other types of machines on the market. The cost of the equipment has been reduced through designing and applying common systems for both lines (2 for 1) and minimize spares between the two machines.
Benefit #3: Executing two TMs at the same time was shortening of the delivery time due to optimized execution cycles – approx. 10 months ready for shipment. As components are interchangeable between the machines the YFY staff has had a chance to get familiar with equipment faster and save costs on replacement parts.

Added value for the future

The machines run smoothly and efficiently and are great tools to produce high quality tissue made of virgin fibres reaching production goals (160 t/d in total). They are flexible as they are based on proven Crescent Former technology (the leading concept worldwide for tissue production). The mill has gone through production trials reaching from time to time the operation speed on machines: 5580 fpm (1700 m/min) and a result increasing daily production capacity by 25% (from 160 – 200 t/d on both machines). The machine design is modern and compact and as a result, downtime can be reduced to a minimum (estimated: 12 days a year – a number already achieved on machines PM#5 and PM#6). Operators appreciate smart and user-friendly solutions that support efficient clothing changes (change time: for wire – one hour, for felt – up to two hours). Two people are enough to run the entire line from stock-prep up to the rewinder. Machines are definitely eco-friendly which is confirmed by low media consumption.

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