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Articolo pubblicato nel fascicolo di Ottobre 2023 di Carta & Cartiere TISSUE MACHINE

WORLD CLASS TEAM AND WORLD CLASS EQUIPMENT MAKES WORLD SPEED RECORD

To run a tissue machine at high efficiency, producing great tissue quality at optimum environmental footprint and at the same time getting the most out of capacity is an art itself. And, if you at the same time are running the machine at a very high speed and high efficiency, it’s exceptional. In early April 2023, Fine HH’s Al Nakheel mill in Abu Dhabi (UAE) reached a truly magic moment when they hit a new world record speed, operating at 2222 meter per minute for 24 hours!

di: Valmet

To reach this level of operational excellence, a lot of things must come together. First of all, the running conditions needs to be perfect with optimized process settings, chemistry, raw material and production planning. The application of autonomous and preventive maintenance programs, continuous improvements and corrective maintenance is also essential. But even more important is the capability building of each and every one of the team in technology, operation, AM systems, PM systems and focused improvement.

“I am very proud about this extraordinary, fabulous performance. To achieve a world record demands two major things: a world class team and world class equipment. The team showed that anything is possible when you have absolute focus, engagement, enthusiasm and skill” – says Wolfgang Lied, Chief of Operations, Product development and Engineering at Fine Hygienic Holding.

Heading for the best

Fine Hygienic Holding was established in Jordan, 1952 by Elia Nuqul. Today they operate 10 tissue paper factories in Jordan, Egypt, Saudi Arabia and United Arab Emirates. Starting as a converting company, developing into tissue production, they have been on a steady growth path and is today considered to be one of the leading tissue companies in the MENA region.

Samir Masoud, UAE Supply Chain Director at Fine Hygienic Holding.

Their strategy has always been to employ best technologies, people and suppliers to produce high quality tissue products. The collaboration with Valmet started in 1990 with the delivery of a tissue machine to the Al Bardi mill in Egypt.

During the years Valmet has supplied additional three tissue machines to the company where the most recent is the Advantage DCT 200TS line equipped with the latest technology, to Al Nakheel mill in Abu Dhabi which started up in September 2017.

Challenging the status quo

With trust in the robust Valmet technology and the highly skilled people with their “can-do” attitude, the Al Nakheel team decided to optimize the tissue machine performance to increase the capacity and boost volume. The journey started in June 2022 running at 2000 m/min. Already two months later they were operating at 2100 m/min.

After careful validation and inspection of critical equipment and parameters including the whole production system from stockpreparation to tissue machine, winder and wrapping/packing unit they geared up to 2200 m/min and has continued ever since.

“The main enablers for this huge achievement were team capability and Valmet robust technology” – says Khalil Shorbaji, PM 5 Operations Manager at Al Nakheel in Abu Dhabi.
Abdelhadi Alhader, Technical Support Manager, Fine Hygienic Holding.

Thanks to the stable operations at such high speed, the idea to go even higher became tempting. They brought the idea to their mill team who immediately took on the challenge. April 2023 was a historical moment when they achieved the world record speed of 2222 m/min for 24 hours.

“The Advantage DCT machine has performed very stable and reliable during the journey to gear up the machine speed from previous 2000 meter per minute to where we are today. This great achievement was reached while producing 13,2 gsm facial tissue at 96,5% efficiency. It is just amazing! – says Samir Masoud, UAE Supply Chain Director at Fine Hygienic Holding.

Sustainability is important to Fine HH: they were the first paper mill to sign to the United Nations Global compact. They adopt best practices to conserve resources, e.g. water reservation practices, water treatment, waste recycling, replacing heavy fuels and reducing CO2 emissions. It was of course a challenge to ensure low environmental footprint at the same time as raising the speed.

“This huge accomplishment was coupled with great savings. While reducing energy and water consumption, we also lowered the carbon footprint in compliance with the sustainability goals to pass on a healthy environment to the next generation” – concludes Abdelhadi Alhader, Technical Support Manager, Fine Hygienic Holding.

Waheed Al-Qannas, Mill Sales Manager, Valmet – Samir Masoud, Fine HH – Kent Nika, Sales Director, Valmet.

Also, Valmet, who has supplied the tissue line to Fine HH, sees this as a significant milestone in the common journey and a moment to be proud of. “We at Valmet are impressed of the great achievement which came true by dedicated people, best technology and the long and fruitful collaboration” – says Waheed Al- Qannas, Mill Sales Manager, Valmet.

Technical information

  • Advantage DCT 200 tissue line
  • 5.6 meters wide
  • Operating speed 2,000 meters per minute
  • Capacity 65,000 tonnes per annum

Key technologies
OptiFlo II TIS Headbox, Advantage tissue technology, including ViscoNip press, AirCap Heli hood, Yankee dryer and SoftReel reel.

Additional technologies
Valmet Stock preparation equipment and Focus Reelite Rewinder

Additional services
Installation supervision, training, start-up and commissioning

The main enablers to achieve the speed record was team capability, a culture of “Run to target” mentality and Valmet robust technology.
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