Blog Post

Italy’s Recard develops new Easy Crescent tissue machine

(Lucca, Italy, Dec. 6, 2016) Listening to customers’ needs allows creating tailor-made machines, but it also spurs us to innovate and to develop new technologies. To meet the demands of the global market, in the last few years Recard has increasingly focused on developing projects to install tissue machines simply and economically.
This is how the Easy Crescent was born: a machine fruit of the natural progress, in terms of technological innovation, of the experience that Recard has acquired in 54 years of business activity, with the manufacture and installation of almost 130 tissue machines throughout the 5 continents. A customized solution at a limited economic investment – also in terms of ancillary works – low energy costs, easy to install and to manage.
The Easy Crescent is designed to meet the demands of those companies approaching the field of tissue production for the first time (new investors or converters who want to begin producing paper internally), companies wishing to increase their production capacity at a reasonable investment or those who intend dedicating a machine to the production of medium-high basis weights, all the while maintaining a high level of flexibility and minimal operating costs.
Keeping the needs of this important share of the tissue machine market in mind, Recard has designed a medium-sized plant having a good production capacity (from 40 to 90 tpd), with a maximum operating speed that does not require too many sophistications. A plant that is easy to run and maintain, with strong, reliable equipment, no technical compromises to reduce the price, with leading-edge technical solutions to diminish energy consumption and hence operating costs. Although the Easy Crescent is not Recard’s flagship machine – the company can boast of many machines with a high operating speed and 6 running continuously at 2000 m/min – it embodies all the company’s know-how gained in its over fifty years of business experience, and possesses great advantages in many aspects.
Characteristics and advantages of the Easy Crescent
The key words for the Easy Crescent are simplicity and savings. Simplicity as far as installation is concerned, above all. Stock preparation, approach system, the machine itself and the rewinder are installed at the same level (zero level). This is possible thanks to the special silo design and to an accurate choice of the fan pump. The wire section has a special “C-shaped” structure that allows eliminating the expensive civil works necessary to anchor the cantilever. Additionally, the Easy Crescent is equipped with a special broke pulping system – very small and highly efficient – placed in a small pit just 2 meters deep. All these features have the scope of minimizing civil works and making the installation of the plant possible also in existing machine halls that were initially intended for other uses.
The machine has a configuration featuring a blind-drill press roll only – hence it is not equipped with suction press roll – and is served by just one vacuum pump. At the speeds at which Recard tested the machine, the post-nip dryness level easily reaches 39%, a value identical to the one obtainable with a suction press roll.
The plant can be supplied with different energy saving solutions. The basic configuration features a single-line stock preparation system and a very short water circuit. The main pulper has a special high-efficiency, average-density impeller. Stock chests are equipped with special, low energy consumption vertical agitators. On the thermal side, the machine is equipped with a steel Yankee cylinder with heads insulation. If the machine is equipped with a gas hood, it is possible to install an integrated recovery boiler that can produce up to 30% of the steam required by the Yankee by using the exhaust from the hood itself.
The Easy Crescent is basically a concept, but, like all of Recard’s plants, it can be completely adapted and modified based on customer requests. For example, it can be equipped with every type of stock preparation unit, both for virgin and recycled fibers. The system can have different production capacities thanks to the possibility of installing different Yankee sizes and hood types (gas, steam, mono-system, duo-system, etc.).
Its advantages are assessed in terms of:
Reduced investment for machines and for the necessary civil works
Space savings: compact plant with minimal installation space required
Simplification of civil works
Easy installation, operation, and maintenance
Reduced energy consumption
Operational costs reduced to a minimum.
This machine is ideal to produce medium-high basis weights because its operational speed is limited by the use of a blind-drill press and by the fact that the fan pump has a minimal suction head.
The first Easy Crescent, designed for 1000 m/min, was supplied to the Italian Group Carrara in 2001 and is still running at design speed. After a series of modifications and implementations by Recard, 1300 m/min were reached with the Easy Crescent supplied to the Celtex Group in 2012. In the recent installation of Papergroup’s PM3, the machine attained 1400 m/min with no technical issues of any kind. An extraordinary result that was retained impossible to achieve and that leaves the possibilities open to test the machine at even higher speeds, and to propose this type of machine not only to companies who are just entering the market, but also to those who have been in business for some time.
The Papergroup case-in-point
The results obtained on the Easy Crescent supplied to Papergroup in 2015 are index of the revolution that this machine can bring to the tissue market.
The goals that the paper company has set for itself in 2013, before embarking on the PM3 project, were:
Minimizing investment
Medium drying capacity of the plant. Initial production demand was 18,000 tpy
Using the existing machine halls, whose size was rather limited
Installing a highly flexible system suitable for meeting the group’s internal needs as well as for the sale of mother reels
Having a plant that was easy to manage
Producing high quality paper
Having a plant pre-arranged for a future increase in production capacity
Minimizing production costs in order to be highly competitive on the market.
“Before buying the Easy Crescent,” explains Claudio Bianucci, Plant Manager of Papergroup, “we contacted several suppliers. But then we decided for Recard because it was the company that fully met all the project’s requirements. Recard’s aptitude for adapting its plants to the needs of customers allowed us to work in close collaboration since the beginning and to elaborate a wholly tailor-made system.” The project entailed the installation of a 12-foot steel Yankee and a gas hood that allowed a maximum drying capacity of 90 tons. A recovery boiler for the hood exhaust was added, too, to produce part of the steam necessary for the Yankee.
The machine, the rewinder and all ancillary services (air system, electrical system, stock preparation) were installed in the 1530 m2available in the existing machine hall. Despite the small amount of space, thanks to the synergy between Papergroup and Recard, a very rational layout was created with very short piping and cables that minimized energy loss. Thanks to the fact that Recard machines are all very low – also in view of minimizing vibrations – the Easy Crescent was able to fit perfectly in the 7250 mm of useful height.
The simplicity of the plant and the rational setup of the machines allow operating the line with just 3 people per shift. “For the installation of this new line,” continues Bianucci, “15 new people were hired who had no previous experience in the paper field. After a period of classroom training, two-thirds of them were employed to start up and operate the new plant with the support of those who previously worked on the existing machine.” Plant start-up was vertical and the machine, after ten days of commissioning, began producing 24 hours a day. “Being able to startup and run the plant with just 5 ‘expert’ people”, underscores Bianucci, “and immediately beginning production is proof of how easy this plant is to operate.”
The quality of the paper is very high and identical to that produced on a standard Crescent Former in single suction press roll configuration. Thanks to the very short pulp and water circuits, the plant is very flexible and suitable also for the future production – with some small modifications – of colored paper.
“The machine’s installation times,” concludes Bianucci, “were in-line with expectations and the budget was respected. The total cost of the plant turned out to be at least 15% lower than what we would have spent by installing a standard plant having the same production capacity.” Operational costs, too, are reduced to a minimum: the plant is operated by just 15 people directly; water consumption is in the order of 5 m3per ton; specific energy consumption is around 750 kWh/ton; specific thermal energy consumption is 1570 kWh/ton and total specific energy consumption is 2320 kWh/ton of paper produced.
Given the optimal results obtained with the Papergroup machine, Recard wishes to continue developing the Easy Crescent technology in order to exceed the limits attained in terms of operation speed, energy consumption and installation costs. (Source: press release)
Cover Image: a Recard tissue machine / courtesy Recard (representational purposes only)

Leave a Reply

Your email address will not be published. Required fields are marked *

Related Posts

Toscotec to Supply Lucart with New Tissue Machine in Italy

(Italy, Dec. 14, 2017) Toscotec announced that it will supply Lucart Group with a

A.Celli to supply five tissue machines for Yibin Paper Industry in China

(Italy, 27 November, 2017) A.Celli Paper received an order confirmation from Yibin Paper Industry

Södra Invests in More Forestry Drones

(Sweden, Nov. 27, 2017) Södra is now investing in more forestry drones. This digital

Andritz Starts Up TM5 Tissue Machine Supplied to Guizhou Chitianhua Paper in China

(Graz, Austria, Sept. 7, 2017) Andritz announced that it has successfully started up the

Suzano Starts-Up New Tissue Production Line at Mucuri Mill

(Sao Paulo, Brazil, Sept. 12, 2017) Suzano Papel E Celulose S.A. announced that it

Voith to supply The Navigator Company with new tissue machine in Portugal

(Heidenheim, Germany, August 7, 2017) Voith said that it will supply The Navigator Company

Vinda Paper starts up two Toscotec supplied machines

(China, July 18, 2017) Vinda Paper Zhejiang fired up two Toscotec supplied tissue machines,

Accrol Group invested Euro 4.5 million in a new tissue converting machine

(U.K., 07 July 2017) Accrol Group Holdings has invested Euro 4.5 million in a

Valmet to Supply a Complete Tissue Production Line to ICT Iberica in Spain

(Helsinki, June 28, 2017) Valmet will supply a complete tissue production line with an

Pmp’s Tm1 at Hebei Jinboshi Group has been brought on stream

(China, 04 Jul 2017) On 22nd January 2016, PMP -- a global provider of

Valmet to Supply Hayat Kimya with New Tissue Machine in Tartaristan, Russia

(Helsinki, Finland, June 27, 2017) Valmet said that it will supply an Advantage DCT

Georgia-Pacific Selects Palatka, Florida Mill for $400 Million Tissue Machine Project

(USA, June 23, 2017) Georgia-Pacific today announced that its Palatka, Florida, mill has been

Valmet to Supply Tissue Production Line to Sofidel in Spain

(Helsinki, Finland, June 19, 2017) Valmet will supply a complete tissue production line to

Orchids Paper Starts Up New Tissue Paper Machine at Barnwell, SC

(USA, June 12, 2017) Orchids Paper Products announces the startup of its new 100%

Tissue machine started up at Paper Trime in Portugal

(Lisbon, 19 May 2017) Paper Prime, a company belonging to the Trevipapel Group, and

SCA to Close Tissue Production Plant in the Flagstaff, Arizona

(USA, June 7, 2017) SCA said that it has decided to close the tissue

Andritz starts up twelfth tissue machine for Hengan Group

(Graz, Austria, May 05, 2017) Andritz has successfully started up the tissue machine supplied

Ariete chooses Toscotec for the installation of a new tissue machine

(Italy, April 06, 2017) Ariete S.r.l., Italian company producing high quality tissue paper, has

Italian tissue paper machine maker seals Bolivian contract

(Italy, April 10, 2017) Italian tissue paper machine producer GapCon Tissue S.r.l. has obtained

Wepa starts up the new tissue machine at its Piechowice plant

(Poland, April 10, 2017) Wepa Group announces the successful start-up of the new Toscotec’s

Valmet to supply Irving Consumer Products with TAD Tissue Machine

(Helsinki, April 7, 2017) Valmet announced that it will supply a new Advantage ThruAir

Toscotec receives eight orders from APP; scheduled to come on stream in Q4 2017 and Q1 2018

(Italy, April 04, 2017) Toscotec has received in total 8 (eight) Tissue Machine order

Efficient production with Voith XcelLine tissue machines

(Heidenheim, Germany, April 05, 2017) Tissue World in Milan will be the ideal place

Resolute Forest Products Starts-up New Tissue Machine at Calhoun Mill in Tennessee

(USA, March 29, 2017) Resolute Forest Products today announced the successful start-up of its

EuroVast has chosen Toscotec to expand its Botticino plant; the new TM with a maximum production capacity up to 30,000 tonnes/year

(Italy, March 24, 2017) The new machine, a MODULO-PLUS crescent former with single press

Link: Diaper-wearing baby boomers are a boon for paper industry

(London, March 10, 2017) As population ages, sales are climbing for absorbent hygiene products.

Hayat Kimya started up new tissue production line in Egypt

(Cairo, Feb. 27, 2017) Hayat Kimya’s started up a new tissue machine (TM6) in

Recard to supply Star Paper mill with new tissue production line in Abu Dhabi; capacity 38K t.p.a.

(Italy, Feb. 28, 2017) Recard announced that it will supply Star Paper Mill Ltd.

(Image: courtesy A.Celli Paper)
A.Celli Paper to supply new tissue machine to Grupo Corporativo Papelera; capacity 34K t.p.a.

(Italy, Feb. 28, 2017) A.Celli Paper to supply a high-speed tissue machine with a

SCA to invest $105 million in tissue plant in Mexico

(Mexico, Feb. 24, 2017) SCA will invest about USD 105 million (approx. SEK 950m)

Chinese company to build biggest paper mill in Ethiopia

(Addis Ababa, Jan. 17, 2017) China Engineering Corporation (CEC) has signed an agreement with

Romanian tissue paper production up 16% in 2016

(Bucharest, Romania, Feb. 21, 2017) Romanian tissue paper makers managed to expand their total

Clearwater Paper announces second tissue machine and converting facility in North Carolina

(Shelby, USA, Feb. 9, 2017) Clearwater Paper today announced plans to build a new

Romanian tissue paper maker secures €24M to increase output capacity

(Bucharest, Romania, Feb. 06, 2017) Romanian tissue paper producer Pehart Tec has obtained a

Four Valmet supplied tissue lines started up within three months at Lee & Man Paper Manufacturing in China

(Helsinki, Finland, January 30, 2017) Four Valmet supplied tissue lines has been successfully started

Two new Toscotec’s tissue machines delivered to Vinda Paper; will bring a further increase of 60,000 tons/year

(Italy / China, Jan. 24, 2017) In December 2016, the Italian supplier Toscotec S.p.A.

SCA Strengthens Its Tissue Business in the UK

(London, Jan 26, 2017) SCA has announced a number of measures to meet the

First Quality Tissue to expand its operations in Lock Haven, Pennsylvania

(USA, Jan 10, 2017) First Quality Tissue, LLC a manufacturer of ultra-premium towel and

Link: Chinese Firm to Build Pulp and Paper Factory in Ethiopia

(Addis Ababa, Ethiopia, December 27, 2016) A newly-established joint venture Purewood Pulp, Paper and

Toscotec to deliver two tissue machines to Hengan Group

(Italy, Dec. 20, 2016) Hengan Group, a leading Chinese manufacturer of tissue and hygiene

Poland’s Abek launches tissue paper plant

(Poland, Dec. 20, 2016) Polish tissue paper maker Abek sp. z o.o. has launched

PCMC to Supply Tissue Converting and Packaging Line to Bedford Paper

(USA, Dec. 15, 2016) Paper Converting Machine Company (PCMC) recently announced that it will

Ontex opens new tissue plant in Dourges, France

(France, Dec. 12, 2016) Ontex Group officially opened its new production site in Dourges,

Romanian tissue paper maker expands sales by 30%

(Bucharest, Dec. 13, 2016) Romania’s tissue paper producer Pehart Tec raised its sales by

PPC completes $5.8 million expansion project

(Kaukauna, WI., USA, Dec. 14, 2016) Precision Paper Converters (PPC) announced the completion of

Nippon Paper Crecia and Kasuga Paper Industry form tissue production joint venture in Japan

(Tokyo, Japan, Dec. 6, 2016) Nippon Paper Group announced that Nippon Paper Crecia Co.,

Toscotec to rebuild PM1 tissue machine at Correll Tissue in Durban, South Africa

(Italy, 06 6 December, 2016) Toscotec has been awarded a contract to rebuild PM1

Kyiv CPM installs new Yankee-cylinder

(Ukraine, December 02, 2016) Kyiv Cardboard and Paper Mill’s (Kyiv CPM) paper machine with

Clearwater Paper to close Oklahoma city tissue converting facility and restructure Neenah mill

(Spokane, USA, Nov. 29, 2016) Clearwater Paper Corporation (CLW) today announced the permanent closure

Case Paper Completes Installation of New Sheeter

(New York, Nov. 30, 2016) Case Paper announced that it recently completed the installation

Savcor upgrades Stora Enso’s Skutskär mill with new corrosion prevention system

(Sweden, Nov. 23, 2016) Stora Enso Pulp AB Skutskär strengthens the performance of digester

First Quality Tissue Announces Plans to Install Two New Tissue Machines

(USA, Nov. 21, 2016) First Quality Tissue today announced that it will install two

Gomà-Camps orders new paper machine

(Heidenheim, Germany, Nov. 18, 2016) Gomà-Camps Consumer, SLU, company owned by Gomà-Camps Group and

New ultra-modern case maker for parent company in Oudegem

(Oudegem, Belgium, Nov. 15, 2016) VPK's parent company in Oudegem, Belgium, has a new,

Andritz to upgrade bleaching system for Cartulinas CMPC in Maule, Chile

(Graz, Austria, Nov. 16, 2016) International technology Group Andritz has received an order from

Atlas Packaging invests GBP 1.75 million ($2.2 million) in new corrugated machinery

(Barnstaple, UK, Nov. 16, 2016) Atlas Packaging invests over GBP 1.75 million ($2.2 million)

Cellwood to deliver a hot dispersing unit to Shandong Tiandiyuan Paper in China

(Shanghai, China, Nov. 06, 2016) Cellwood Machinery Trading Shanghai has signed an agreement for

Poland’s Velvet Care to invest €37M, expand workforce

(Warsaw, Poland, Nov. 14, 2016) Polish tissue paper maker Velvet Care is implementing an

Twinsaver to become the largest tissue manufacturer in Sub-Saharan Africa

(Johannesburg, South Africa, Nov. 09, 2016) Twinsaver Group, the major manufacturer of tissue products

German tissue paper maker upgrades Polish plant

(Switzerland, Nov. 08, 2016) German tissue maker Wepa Professional Hygiene has awarded a contract

Link: Swedish paper giant may ditch timber to focus on growth markets: the fast growing hygiene sector

(New York, Oct. 23, 2016) SCA recently announced plans to spin out its paper

SCA to invest nearly $24 million in its Kentucky plant

(Sweden, Oct. 25, 2016) SCA, a global hygiene and forest products provider, will increase

Valmet to supply two Advantage NTT tissue production lines to Sofidel’s Greenfield mill in Ohio

(Helsinki, Finland, Oct. 13, 2016) Valmet announced that it will deliver two Advantage NTT

Charmin makes it easier for consumers to choose responsibly sourced tissue products

(Cincinnati, USA, Oct. 10, 2016) New On-Pack Seal Communicates Charmin’s Partnership with Forest Stewardship

Sofidel is to start up two new Valmet Advantage NTT 200 tissue machines in Circleville (Ohio); 70,000 tonnes/yr of capacity

(Porcari, Italy, Oct. 05, 2016) The announcement was made yesterday by Sofidel CEO Luigi

Valmet to supply a rewinder to Roto-cart in Italy

(Helsinki, Finland, Sept. 30, 2016) The Italian tissue converting company Roto-cart Spa has selected

SCA closes baby diaper business in Mexico

(Stockholm, Sweden, Oct 03, 2016) As part of SCA’s work with addressing weak market

ST Tissue Announces $35 Million Capacity Expansion Project at Franklin, VA Mill

(Franklin, Virginia, USA, Sept. 29, 2016) Tak Investments, owner of tissue mills in Oconto

Link: IIT Hyderabad develops sanitary napkins that absorb better

(Chennai, India, Sept. 27, 2016) The absorption capacity of napkins with nanofibre was higher

A Celli to deliver rewinder to Sofidel

(Lucca, Italy, Sept. 28, 2016) A.Celli Paper has recently concluded an order for a

Valmet to rebuild Metsä Tissue’s tissue machines in Raubach in Germany and Pauliström in Sweden

(Helsinki, Finland, September 21, 2016) Metsä Tissue has selected Valmet as supplier for the

CMPC signs contract with Voith to supply new tissue machine

(Heidenheim, Germany, Sept. 21, 2016) CMPC has signed a contract with Voith Paper for

Andritz received order from Bashundhara Paper

(Graz, Austria, Sept. 20, 2016) Andritz has received an order from Bashundhara Paper Mills

The largest TT SYD ever installed in Europe successfully started up

(Italy, Sept. 16, 2016) The biggest European Steel Yankee Dryer for tissue production, a

Hengan Starts Up Valmet-supplied Tissue Line in Wuhu, China

(Helsinki, Sept. 6, 2016) Valmet announced that an Advantage DCT 200HS tissue line supplied

Ten Toscotec tissue machines up and running at Vinda’s Sanjiang (China) mill

(Italy / China, Sept. 06, 2016) Vinda Paper (China) Co., Ltd. in Sanjiang mill,

Resolute’s Calhoun Tissue Operation on Track for First-Quarter 2017 Start-Up

(Calhoun, Tennessee, USA, Sept. 7, 2016) Resolute Forest Products today announced completion of commissioning

Andritz successfully starts up tissue machine with steel Yankee for Guangdong Shaoneng, China

(Graz, Austria, August 25, 2016) International technology Group ANDRITZ has successfully completed start-up of

Voith Paper to Supply Little Rapids’ Shawano Mill with New Tissue Machine

(Heidenheim, Germany, Aug. 22, 2016) Voith Paper said that it will supply Little Rapids

Cheng Loong TM 16 successfully passed its guarantee test

(Taiwan, August 17, 2016) In Taiwan the Cheng Loong TM 16 tissue machine provided

Voith to supply two tissue machines to Lee & Man; startup is expected to take place in September and July of 2017

(Heidenheim, Germany, August 11, 2016) Voith signed a contract in June 2016 with Lee

Valmet Advantage TAD tissue machine
Kruger Products to Invest $55 Million in New Tissue Machine at Its Crabtree Mill

(Canada, July 25, 2016) Kruger Products L.P. today announced it is investing $55 million

(Image: courtesy A.Celli Paper)
Four tissue rewinders for Lee & Man Paper

(Porcari, Italy, June 29, 2016) A.Celli Paper has recently concluded an important agreement with

(Image: courtesy A.Celli Paper)
Four tissue rewinders for Lee & Man Paper

(Porcari, Italy, June 29, 2016) A.Celli Paper has recently concluded an important agreement with

Andritz to supply two tissue machines to Guizhou Chitianhua in China

(Graz, Austria, January 26, 2016) Andritz said that it has received an order from