Founded in the interior of Santa Catarina, in the municipality of Três Barras, Mili S.A. today is a source of pride for Brazil. It is among the largest tissue paper manufacturers in Latin America, and one of the only factories in all of Latin America with an installed capacity reaching 200 thousand tons/year. “Today, we are proud to say that we have the largest paper conversion on a single site in Latin America,” said Valdemar Lissoni, President of Mili.
Rewinders are an essential part of any tissue converting operation, and their performance largely drives production success. The current 3- and 4-roll rewinder configurations are both popular in the field.
However, as converters gain comparative experience they are discovering significant advantages in using 4-roll rewinders, particularly as it relates to improved roll control and exceptional winding geometry design.
Let’s briefly explore some of the benefits a 4-roll rewinder could provide to your operation.
Facial tissue. Hand towels. Napkins. Folded tissue products remain in demand. Growth rates in North America are projected at 1.8% annually through 2025, and away-from-home (AFH) product trends point to a 2.3% increase during that same timeframe.
As few as 20 years ago, tissue embossing was mainly considered a volume-generating process. There were one or two design engravings available, both of which had a mechanical function — creating volume for rolled tissue product packs. Customers chose one or the other engraving pattern. There was no differentiation on the shelf.
In the ensuing years, tissue embossing transitioned from mainly functional to mainly aesthetic. As competition ramped up within the tissue industry, so did the number and type of embossing designs. Tissue manufacturers clamored for exclusive engravings and most were obliged. However, the focus on aesthetic designs came at the expense of the mechanical paper characteristics. Beautifully embossed rolled products pleased the eye, but were often scratchy, flimsy, and non-absorbent.
Packaging is a constant need, yet a market of shifting dynamics. Current trends could be — and have been — replaced by more popular iterations. Changes in packaging standards necessitate change in materials and/or processes.
Such shifting priorities can complicate packaging equipment selection. How do tissue converters confidently choose wrappers and bundlers that have the core package formats to meet current market demand, yet also have the flexibility to adapt to future roll product needs?
Embossing systems are necessary and expensive equipment options tissue manufacturers use to differentiate their products or enhance product attributes. The use of exclusive embossing patterns introduces signature designs. Embossing also can influence certain tissue characteristics such as bulk, softness, and appearance to enable rolled tissue products to compete for market share alongside higher-value options.
Fabio Perini is no stranger to technology. As a leader in the tissue industry, we’ve innovated Industry 4.0 artificial intelligence-based solutions that target specific customer needs.
Our global Tissue Performance Center data scientists are able to continuously collect, and analyze production line performance data. In turn, the data is used to provide information on the status of machines and Overall Equipment Effectiveness (OEE) for customers throughout the world — from one remote location.
Consumers evaluate brands on the shelf and often make purchase decisions based on primary packaging. How the product is presented makes a statement.
For tissue converters, getting toilet tissue and kitchen towels to market can be challenging due to the sheer number of pack configurations used — from single rolls to 90-roll multi-packs. Equipment must be versatile in order to provide seamless changeovers. There’s also the increasing importance of sustainable packaging materials. Transitioning from poly to paper requires careful consideration as not all machinery is adaptable. It all adds up to potential production line inefficiencies, and no OEM can afford wasted time or money.
In the tissue paper production market, few companies are in league with the Sofidel Group. The headquarters remains in the founding city of Porcari (Lucca), Italy, but much has changed since 1966.
Today, Sofidel is established in 12 countries throughout Europe and the United States of America, managing more than 1.3 million tons of collective annual tissue paper production.
Downtime is a time-consuming and expensive disruption for tissue converters. It can be managed in some instances — such as for machine maintenance. By and large, though, downtime is a detriment that the American Productivity and Quality Center (APQC) estimates accounts for losses of up to $1.20 for every $20 in revenue.1