TP-StopLess. The innovative NON STOP Reel Change method in Tissue Winders (Patent pending)

When winding tissue there are many factors that limit the winders operating speed. On “conventional” tissue products the main limiting factors are: paper width, number of plies, diameter of cores at wind-up, number of slitters into operation.

author: Mauro Della Santa, Sales Manager, Tecno Paper Srl

Industry Insight by:

Tecno Paper Srl

When talking about “Super Soft” tissue, whose reels (mother and finished ones) have a low density and the structure of the web is more sensitive to permanent deformation, to the above factors we have to add the high relieving actions on chucks and rider rolls, necessary to keep tissue properties, that reduce the reels stability at high speed. In order to keep high the productivity of tissue winders, enabling them to match the output of tissue machines, also in those cases where speed cannot be raised, Tecno Paper has developed, and patented, rewinding methods able to increase the operation efficiency significantly. We mean that for the productivity “speed is not all”, but efficiency has a great impact. The most recently developed and patented method is the TP-StopLess, a Non Stop finished reels change system.

The main feature of this winding method is that the working speed is only slightly reduced and there is no intervention of the winder operator in the phase of reel exchange and evacuation from the winding position. From the points of view of the quality of the initial winding (keeping tissue properties) of the new reel and of the stability of both reels (newly forming and finished ones), the method allows the best conditions because both reels are constantly supported and in contact with the carrying drums; this allows the NIP against rolls and the entire winding operation are fully controlled from beginning to end, thus avoiding the bad situation that one of the two reels moves freely. Compared to a traditional winder for conventional tissue, the StopLess model has several additional elements, as evidenced in picture 1.

Picture 1


We see one additional roll (Change Roll) close to the rear carrying drum, a pivoting system for the new forming reel, additional chucks (Secondary Chucks) and a particular finished reel removal system (that is a positioner) in place of the traditional hydraulic pusher. For ease of explanation and clarity, the operating mode can be summarized in phases:

  • When the winding reel approaches the final diameter, the speed slows down and the new core shaft, hold by secondary chucks, gets in contact with the change roll.
  • Due to speed reduction of finished reel, a tissue sail is forming on rear carrying drum and it is brought back by air blows into between new core shaft and change roll.
  • A new tissue reel starts formation and the removal system moves the finished reel onto the lowering cradle. Now the primary chucks are free and start descending to clamp the new forming reel that is being transferred from change roll to the winding position between the carrying drum.
  • Rider roll is approaching the new forming reel, primary chucks have clamped the shaft of the new reel, secondary chucks retrieves to a waiting position to be loaded with a new core shaft and the cycle starts again.


Tissue Winder with automatic finished reel change.
Tissue Winder with automatic web tension control at unwinder.

Main Features and Benefits offered by TP-StopLess system

  • Efficiency increase of the winder by 15% to 22%, depending of several factors like: number of unwind stands in operation; diameter of parent reels; diameter of finished reels.
  • Very smooth finished reel removal obtained by a dedicated device which gently pulls the reel off the carrying drums and positions it onto the lowering cradle, thus avoiding any deformation to the reel structure. This device has replaced the traditional hydraulic pusher.
  • High precision “Closed Loop” NIP control of reels against all rolls during the entire winding operation (reel growth and finished reel change).
  • No free movement of reels at any phase of winding operation.
  • Bulk and crepe loss reduced at the minimum extent.
  • Control system and HMI are very operator friendly.
  • Integration with TP-Win 4.0 e TP-Service.


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