Toscotec launches new OPTIMA rewinders for top winding quality and efficiency

With six OPTIMA lines as part of turnkey orders by C.A.S. Paper Mill in Thailand, Paloma in Slovenia, Cartiera Confalone in Italy and Essel in Turkey, Toscotec further strengthens its position as advanced technology supplier of complete lines from the tissue machine down to the rewinder. The other two lines were sold to leading tissue manufacturers that remain confidential. The new OPTIMA line preserves the bulk and softness of the parent reels and boosts winding performance, thereby increasing the overall production efficiency.

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Securing softness and quality

Through an innovative combination of center wind assist control of the parent reels, unwinding web tensioning system and rewinding nip control system, the OPTIMA line preserves tissue quality and delivers optimal reel uniformity.

The unwinding stands feature a compensation system for out-of-round parent reels and a Center Wind Assist (CWA) control, which consists of a combination of belt driven and center drive system, which reduces the pressure applied on the paper by the belts of the unwinding stands. Compared with different systems available on the market, this system reduces the generation of dust and the installed power, which is shared between the belt and the CWA through a motor torque sharing design.

OPTIMA’s efficient web tensioning system avoids elongation loss throughout the rewinder. This is achieved by continuously and precisely controlling the speed of the drive motors, also during machine acceleration and deceleration, in order to carefully guide the paper down to the rewinding station, while avoiding stretching it.

The rewinding section features an automatic nip control system, operating through the load cells installed on the rider roll and the core chucks, which send continuous feedback to the control system, so that the actual thickness and bulk of the wound reel is detected and adjusted in real time. As a result, bulk loss is guaranteed to be less than 3% and the elongation loss below 2 units.

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Higher production efficiency

OPTIMA control system delivers the highest operation accuracy by ensuring that the wound reels have the same length and density. Uniform reel density throughout the mill’s working shifts results in an increase of winding efficiency and ultimately converting efficiency.

OPTIMA’s nip control system and the consequent preservation of the bulk properties of the parent reels allow for a reduction of the creping ratio set on the tissue machine, thereby avoiding slowing down the tissue machine and reducing its daily production because of excessive elongation on the rewinder. This results in an increase in the overall efficiency of the tissue line. The OPTIMA rewinder line can be equipped with a fully automated shaft puller, featuring compact design for easy transportation and installation in limited space, and optimal alignment between the wound reel and the puller.