Toscotec launches breakthrough innovations for a more sustainable tissuemaking

INGENIA, a new concept machine for structured tissue

Toscotec has launched INGENIA, a new concept tissue machine to produce premium quality structured tissue paper. The quality generated by INGENIA line is substantially higher than textured tissue and close to Through Air Drying (TAD) produced paper, but using 35% less energy. INGENIA delivers premium quality tissue with lower energy use and lower capital investment than TAD lines. INGENIA’s concept is based on consolidated technologies for premium tissue, building on vast internal know-how of Toscotec’s and Voith’s R&D, and field data validation on TAD and structured paper systems. Paolo Raffaelli, Toscotec Chief Technology Officer says: “The key factor for energy reduction compared to TAD, is that INGENIA achieves significantly higher dryness through non-thermal dewatering on a structured moulding fabric. With TAD, the thermal drying starts from 24-26%, whereas INGENIA achieves a much higher dryness level without using hot air or steam. This maintains the premium quality obtained through rush transfer and structured moulding fabric, but uses much less energy”.

Ultra-premium tissue quality

Through non-compressive water removal technologies and efficient fiber moulding, INGENIA produces much higher tissue quality properties than other technologies for textured or conventional DCT tissue. These properties include bulk, softness, stretch and absorbency, which improve the tactile “hand” feel and the final paper characteristics that compete with premium segments for toilet, facial and towel tissue grades.

Energy efficiency through process innovation

The process of this new concept machine begins with a dilution profiling layered TT Headbox-ML operating on a twin-wire forming section. Like TAD machines, INGENIA operates wire rush transfer at low consistency, but its key capability is an enhanced vacuum de-watering system without pressing the paper web, which ensures that dryness is greatly increased while fibers are being supported in the same shape as they originally formed when fully water saturated. At the end of the wet section, TT NextPress shoe press uses low loading pressure to gently stabilize the web dryness content and transfer the paper to the drying section without bulk compression. The combined action of a third-generation design TT SYD Steel Yankee Dryer and high-efficiency TT Hood achieves the final desired dryness. The process is completed by dry creping, sheet stabilization integrated with dust removal, and precision winding using an electro-mechanical TT BulkyReel fitted with a Center Wind Assist on the primary and the secondary arms. The Center Wind Assist fully preserves bulk by reducing the nip pressure against the reel drum during the winding process.

TT Induction SYD, a breakthrough innovation in Steel Yankee Dryers

Toscotec, the global market leader of Steel Yankee Dryers, has introduced TT Induction SYD, a carbon-reduction breakthrough that redefines Yankee dryer technology entirely. TT Induction SYD uses electrical induction instead of steam energy to dry the paper web, thereby cutting direct greenhouse gas emissions to zero.

A disruptive innovation for dry crepe and TAD tissue machines

With TT Induction SYD, the internal steam distribution and steam/condensate removal systems are entirely replaced by an induction system composed of static coils installed inside the shell and electrical controls and instrumentation located outside for easy maintenance and monitoring. As a result of precise coil geometry, the induction system delivers a very fast and accurate heating effect exactly on the areas of the shell where it is required, while preventing residual circulating currents in other areas. Steam-heated Yankees use steam energy typically generated by burning fossil fuels. TT Induction SYD uses electrical energy that can be derived from renewable energy sources while delivering the same result, i.e. uniformly heating up the Yankee’s shell in contact with the paper web to achieve dryness. Luca Ghelli, Toscotec R&D Director says: “Sustainability is the guiding idea of TT Induction SYD’s design. As a proven industrial technology, an induction system offers multiple advantages when applied to the most energy-intensive section of the tissue machine. The efficiency of this cutting-edge technology will dramatically reduce the carbon footprint of papermaking. Based on our expertise in steam-heated TT SYD and induction systems, we succeeded in developing a more efficient and sustainable steel Yankee dryer”.

Substantial carbon reduction with unchanged productivity and paper quality

Normally, approximately half of the carbon dioxide emissions produced by a tissue machine originate from the operation of the Yankee dryer. By using clean energy, TT Induction SYD achieves zero direct emissions, while maintaining productivity unchanged and reducing energy consumptions because of the higher efficiency of the induction system. Due to the precise heating of the shell, it also eliminates possible moisture profile issues related to uneven condensate removal, thereby ensuring an improvement in moisture uniformity in both cross direction (CD) and machine direction (MD).

Maximum safety, easier operation and maintenance

TT Induction SYD was designed without any electrical, mechanical, and radiation risk to ensure maximum safety. Besides offering safe operations, it also clears all issues related to the maintenance of steam-heated Yankees, including pressure vessel’s mandatory and planned controls, maintenance of condensate straw pipes against potential plugging and of special heads for steam and condensate inlet and outlet. TT Induction SYD simply requires relatively easy maintenance on the electromagnetic induction system.

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