The Mill’s production is divided into 3 main processes: Parent Roll Production, Converting and Embossing, and Wrapping and Packaging

Parent Roll

For Parent Roll production, the Mill will be utilizing two Toscotec Ahead 1.5S Tissue Machines. Once assembled, refined wood stock (i.e. the raw material) is fed into the machine, water is removed and the wood stock is processed into Parent Rolls at the rate of approximately 9 per hour.

Parent Roll Production Equipment: Toscotec Ahead 1.5S Tissue Machine

Left Profile rendering of one Toscotec Ahead 1.5S Tissue Machine

The AHEAD-1.5S standard unit consists of a four-roll cantilevered Crescent Former with a ø 1540 mm forming roll, a single jet headbox (TT Headbox-SLT), a pneumatically loaded TT SuctionPressRollSPR1045, ø 472 mm rolls, a Steel Yankee Dryer TT SYD-12FT (3660 mm) working at max 10 bar (g), a pneumatic Pope reel type TT Reel-P with max reel diameter up to 2600 mm and a Duosystem gas fired hood by Milltech. An alternative upgraded solution of AHEAD-1.5S can include a multilayered headbox (TT HeadboxMLT), a Steel Yankee Dryer TT SYD15FT (4572 mm) working at max 10 bar(g), the hydraulic Pope reel type TT Reel-H with max reel diameter up to 3000 mm and with the automatic reel spool magazine.

Converting & Embossing

As illustrated in the diagram, beginning in the far left, the Parent Roll is first unwound by the “Unwinders” and fed into the “Embosser”. Here, the clients’ custom message (i.e. name, logo, slogan, etc…) is embossed onto the paper product. Next it is fed into the “Rewinder” where it is wound back into thinner rolls (depending on the type of paper product; paper towel, toilet paper, napkin, etc…) which remain 9’ long (same as Parent Roll). Each Parent Roll will supply approximately 200 of the thinner rolls. The thinner rolls eventually make their way to the “Log Saws” where the 9’ sections are cut by a 3’ saw blade into the proper lengths of the final product.

Converting & Embossing Equipment: Gambini Flex 600 Converting Line w/ Touch Max Embosser

Gambini Flex 600 Converting Line w/ Touch Max Embosser

For Converting & Embossing, the Mill will be utilizing the Gambini Flex 600 Converting line with a Touch Max Embosser.

Wrapping & Packaging Process and Equipment: Stax Technologies Packaging Line

The Gambini Flex 600 Converting Line will be paired with a specifically designed, fully automated Stax Technologies high speed packaging line. This optimized system can covert, wrap, box, palletize, and load 750,000 rolls of bath tissue in just 24 hours.