Latest developements of winding technology
A top-class group of specialists and visitors in the field of winding technology met on 12th July 2018 during the Bellmer Winder Day in Niefern to exchange the latest developments in a group of international participants.
The evening before, animated conversations and discussions were already held between diverse producers. Martin Kollmar, President of Bellmer, opened the conference on Thursday officially. Starting with an overview of the recent developments of the Bellmer Group, he introduced the WinderDay concept.
The optimal overall concept
Next, Erich Kollmar, President of Bellmer, presented the relation between winding, transport and rewinding/cutting of secondary rolls. For an optimal overall concept, the respective production steps are first considered independently, afterwards as an entire system with all interfaces. The quality of the winder influences significantly the efficiency and winding quality of secondary rolls.
Depending on the type of paper, this can be done by a conventional winder like the TurboReeler using the BellDur core hardness control. At higher speed and with lower porosity, a center winding unit can be installed on the secondary arm (TurboReeler Pro). For surface-sensitive grades, a center winding is recommended using the rewinding process like the TurboCenter Reeler.
Large capacity rolls can be transported fully automated to the subsequent process steps. TransportCarts connected with an electric shaft safely monitor and reproduce these processes, whether in the position of slitter winder, offline calander, coating station or simply in buffer position. For the automated and efficient connection of the large roll to e.g. the winder, the classic form of the splice at processing speed was adapted to the new form of splices using the TurboButt Splicer. The ButtSplice can splice the “old” paper web (last benefit of an unwinded jumbo reel spool) and “new” paper web, butt-to-butt, using a very thin adhesive tape technology. Consequently, the paper webs can be processed “forwards” or “backwards” without any problem, depending on the specific requirements.
“Four-for-one” – “One-for-all”
The topic of the following presentation by the Finnish Bellmer winding specialist Ahti Peiponen is the new design of the Bellmer TurboWinder. With the motto “Four-for-one” – “One-for-all” the Bellmer Group had designed the new winder together with an interdisciplinary team during the last 2 years and introduced it to the customers. This team was formed by Bellmer specialists who benefit from work phases with Bruderhaus, Gorostidi, GapCon/SRM, and Bellmer.
Progress Report from Italy
Gianluca Scaglioni, responsible for the Italian plants of Reno de Medici Group, shared his experiences and plans with the end section for the production plant in Villa Santa Lucia under the topic “born to be converted“. The Reno de Medici Group operates 6 paper mills as well as 2 sheeting centers. With over 1 million tons of finished products, it is the second largest European manufacturer of cardboard with recycled raw material. The 4,45 m wide machine in Villa Santa Lucia can produce high-quality cardboard at speeds up to 800m/min.
The two previous winders could no longer keep pace with the constantly increasing productivity of the line. Those two winders were operated in parallel with too high personnel requirements. Starting from autumn 2018, the replacement investment with only one TurboWinder will handle the entire capacity of the board machine. The complete automation of the end section enables the fully automatic transport of the jumbo rolls from the winder into the TurboUnwinder. With vacuum support from a TurboFeeder 1.000, the web can now be fed into the TurboWinder. The TurboButt Splicer allows from the second roll onwards a butt-to-butt splice of the cardboard webs during the last set change of the parent roll, in order to ensure a smooth and very efficient rewinding process on different cores. A TambourLift is integrated into the changing sequence to transport the core reels safely and promptly back to the winder. By using a crane, the operators can easily bring the empty reels from the magazine back to the winder of the cardboard machine at any time.
Kolb meets Bellmer
Martin Bergner, plant manager Kolb group in Kaufbeuren, shared further experience about the replacement of a winder in just 5 days with the participants of the Bellmer WinderDay in Niefern. In addition to the high mechanical effort for maintenance works, the existing plant required high personnel capacity, e.g. for manual core feeding, and employees were exposed to high noise pollution. The jointly agreed solution was a new TurboWinder with a reliable one-man operation. As the production plant has been operating at full capacity for years, the key factor of this project was a shortest possible period of replacement of the old winder. “Bellmer was the only supplier who promised less than 10 days of downtime”, explained Martin Bergner. The result of intensive cooperation between both companies was a detailed concept of replacement of the old winder by the state-of-the-art TurboWinder within only 5 days.
Efficiency enhancement in time for winding
Benjamin Schuppiser, Project Manager and Engineer at Bellmer, illustrated how to create winding capacity by means of a second unwinder. Interlocked, fully automated components can gain valuable winding time so that more capacity is again available for cutting the secondary rolls. The comprehensive control concept turns these units into “smart products”, which constantly communicate with each other, work fully automatically and relieve the employee of many work steps.
Automation — Intuitive handling
This is where Jan Jäger, automation specialist at Bellmer, starts with his presentation of the new automation for the TurboWinder. “We analyzed the existing automation from the point of view of the operator and realized new operator-friendly solutions”, explained Jäger. The automation includes the complete control system with all winding functions, drive control, fully automated knife positioning, core management, safety queries, and functions as well as the interfaces in a central processor unit (CPU). Like this, the entire winding process can be controlled or monitored with a visualization either from the operator’s view or from the automation view. Probably the most important tool is the diagnostic system, which, in addition to the usual control codes, also provided the necessary information in an understandable text mode at any time.
Special characteristics of Fluff Pulp
Markus Elsemann, engineer at Bellmer, presented the characteristics of Fluff Pulp. For example, if the density of folding boxboard is 990 kg/m², Fluff Pulp only reaches 55 kg/m². The number of production plants where the pre-dried cellulose web is being transported as roll goods in addition to the classical bale processing of a cross cutter increases constantly. A reference machine processes cellulose webs with an uncut working width of 4.260 mm and cuts up to 15 secondary rolls with diameters of 980 to 1.500 mm. The key for the winding success is the changed web run of the two-drum concept. In this way, the necessary line loads, web tensions and corresponding torques can be precisely inserted into the web by means of the Rider Roll.
Winding Quality to touch
The WinderDay ended with a factory tour of Bellmer in Niefern. The highlight was the final assembled end section with TurboTransporter, TurboButt Splicer, TurboFeeder 1000 and TurboWinder for folding boxboard. The participants had the possibility to view the previously explained machine units, concepts, and work steps and discuss with the Bellmer specialists on site. The combination of technical lecture, discussion, and exchange with specialists was very well received by all attendees.