Saueressig’s “Haschur” technology – increasing efficiency, product quality and supporting the achievement of sustainability targets

The principle is simple, but brilliant. Instead of using closed figures in the embossing designs of the top roller, continuous lines are replaced by shorter sections like small lines and dots. This reduces the bonding area and consequently the amount of glue needed – resulting both in material savings as well as improved properties of the final tissue product in terms of its softness. All this is done without affecting the properties of ply bonding and delamination was not observed in any trials.

Comparisons of existing and reworked designs incorporating the Haschur technology show that the bonding area can be reduced by up to 50%

Beyond that, the Haschur technology leads to increased productivity as it allows the production line to run at higher speeds.

Inspired by design, driven by technology

According to feedback by customers, the production speed can be increased by up to 20%, with consistently strong ply bonding

Issues of efficiency and sustainability are addressed equally by the Haschur technology developed by Saueressig, while keeping up with or even exceeding existing quality requirements placed on the final product. In tissue production, this manifests in resources savings with respect to the materials, such as glue, and in lower over-all energy consumption by establishing a more efficient machine output. To achieve more sustainable production requires a resource-saving manufacturing tool. The Haschur technology gives manufacturers the possibility of revising well-known designs and proven patterns that can be modified to benefit from the advantages of this method. As well, existing embossing rollers can be reworked according to this principle, which is a fast, cost-effective and sustainable approach as less material is needed compared to the production of a new steel core. After coating, the surface is treated with laser etch engraving, finally resulting in a high-performance tool.

SAUERESSIG offers all common engraving techniques under one roof, including highly developed laser etching technologies, tool engraving and state-of-the-art direct laser engraving processes. These diverse engraving techniques enable Saueressig to provide an ideal combination of creative designs and optimal product properties, allowing the individual arrangement and implementation of embossing elements, the combination of different flank angles as well as seamless, continuous engraving over the entire circumference of the embossing roller. The creative implementation of the surface design is made by experienced designers and experts in consideration of all relevant technical details. Innovations and developments in the field of high-quality embossing tools are accompanied by continuous improvements within SAUERESSIG’s machine construction. The advanced tissue embossing calenders made by Saueressig are used to finish all kinds of tissue materials to realize optical, haptic and functional surface effects – available in different models addressing the customer’s individual requirements.

With the new TPE 900 embossing unit, the existing proven concept is taken to the next level

The TPE 900 is a versatile and flexible calender with a roll face width of 900 mm four lanes to emboss and refine tissue products, offering point-flat, point-point and twin embossing, whilst achieving strong ply bonding. Characterized by backlash-free triple bearings and with integrated bending compensation, vibration-damping components it allows for a stable, reliable and efficient production. With constant investment in the development of resource-saving manufacturing tools like the “Haschur” technology and advanced machine construction designed for high efficiency, SAUERESSIG keeps evolving its offerings to support customers in putting into effect all the individual demands that are placed on the final tissue product, while at the same time increasing efficiency and addressing the achievement of sustainability targets.

SAUERESSIG embossing roller with well-known tissue design before and after reworking according to Haschur technology. Comparisons show that the bonding area can be reduced by up to 50%.