Advanced technologies for efficiency, quality and sustainability in tissue

The conference will be moderated by Massimo Ramunni, Deputy Director General of Assocarta and Secretary of Aticelca, who has been actively involved for many years in the leading technical and regulatory activities of the Italian and European paper industry.

The opening presentation of the MIAC Tissue Conference will provide an up-to-date overview of the tissue industry in Italy and Europe, presenting the latest market data and key industry trends in an increasingly complex and challenging international economic and geopolitical environment.

Starting from an analysis of market dynamics, production trends, and the main challenges affecting global competitiveness, the presentation will highlight the strategic role that the tissue industry continues to play in meeting the needs of modern society.

Special attention will be given to the initiatives being promoted at both national and European level to enhance and communicate the values of hygiene, safety, sustainability, and environmental responsibility that characterize tissue products and the entire production chain. The presentation will also illustrate ongoing activities aimed at strengthening awareness of the social and environmental value of the tissue industry, highlighting its contribution to sustainability goals and responsible development.

Digitalization is transforming the pulp and paper industry by enabling smarter, more efficient, and environmentally sustainable operations. Through intelligent technologies, mills are optimizing production processes while significantly reducing their environmental footprint.

Machine learning-enabled energy management systems analyze consumption patterns to identify inefficiencies and optimize energy use in real time, helping mills reduce carbon emissions, lower operating costs, and improve sustainability. At the same time, predictive maintenance, supported by data analytics and IoT sensors, detects equipment anomalies before failures occur, minimizing downtime, extending asset life, and improving operational reliability.

Digitalization also drives process optimization through technologies such as soft sensors, Advanced Process Control (APC), and machine learning models. A recent ABB APC implementation at a major Italian paper mill delivered significant benefits, including reduced natural gas consumption, lower CO₂ emissions, improved steam network stability, and reduced operator intervention.

The integration of APC and Manufacturing Execution Systems (MES) enables real-time monitoring, quality control, traceability, dynamic scheduling, and data-driven decision-making across both pulp and paper production.

As digital technologies continue to evolve, the industry is moving toward increasingly autonomous operations. Advanced control systems and machine learning applications are helping companies improve yields, reduce costs, increase energy efficiency, and ensure more stable and sustainable production.

In a paper machine, the most decisive phenomena often occur where they cannot be directly observed: inside the nip, beneath the doctoring system, and along the dewatering line. Voith’s innovative measurement solutions bring these hidden conditions into clear view, transforming assumptions into reliable, actionable data.

By making the invisible measurable, operators can verify the actual nip profile and loading conditions, assess the accuracy of doctor blade load distribution, confirm the correct positioning of vacuum boxes and edge deckles, and continuously monitor wear on critical components.

This transparency enables precise adjustments and informed decision-making throughout the process.

The results are tangible: a more stable nip, more uniform moisture and paper profiles, and a more efficient dewatering process. In addition, the surface conditions of critical components, such as functional cylinders and Yankee dryers, can be continuously optimized, extending service life and improving overall machine performance.

In a market that continuously demands advancements in both sustainability and product quality, Valmet is proud to unveil the next step in the evolution of textured tissue. This presentation explores a new dimension of the Advantage™ NTT® platform, where the boundaries between high-efficiency production, premium sensory experience, and visual appeal are being redefined.

By combining groundbreaking developments in machinery technology with next-generation belt materials and patterns, Valmet has developed a concept that delivers a unique visual appearance and an entirely new level of softness and tactile experience. The presentation will highlight the synergy between the company’s proprietary pressing technology and innovative texturing possibilities, demonstrating how these advancements improve machine runnability while optimizing base sheet properties for simpler and more efficient converting operations.

Join us as we showcase how the evolution of NTT now offers tissue producers the opportunity to create their own distinctive signature in the development of products with superior qualities, setting a new benchmark for the future of premium tissue.

Tissue mills are under increasing pressure to reduce energy consumption and CO₂ emissions while maintaining stable product quality and high availability, despite raw material variability and frequent grade changes. Digitalization enables energy efficiency to be managed as an operational discipline through transparent process-level measurements, digital twins for simulating and validating setpoints, AI-based analytics for early detection and predictive control, optimization of hybrid and renewable energy integration, and secure OT architectures that ensure operational continuity.

Digital twins connect energy consumption, process setpoints, raw material properties, and quality outcomes, helping to define robust operating windows, standardize best practices, and reduce dependence on individual operating styles. This approach supports consistent improvements in energy efficiency without compromising product quality.

A primary objective within the tissue industry is preserving paper bulk while minimizing caliper variation in finished reels. This challenge is addressed by Toscotec’s TT BulkyReel, a state-of-the-art Pope reel managed through electromechanical control without the use of oil, helping paper mills achieve a cleaner operating environment.

Toscotec’s solution utilizes Core Wind Assist (CWA) technology on both the primary and secondary arms to provide improved control of the nip load between the paper and the Pope reel drum throughout the entire winding process, from the beginning to the end of reel formation.

This presentation will explain the operating principles of the TT BulkyReel and examine its performance benefits compared with conventional Pope reel technologies.

Toscotec currently has numerous references for both conventional tissue machines and TAD applications. The presentation will highlight the results achieved and the advantages offered by this innovative solution, including selected case studies demonstrating different applications.

The commissioning and start-up phase of a new stock preparation plant is a complex process in which effective troubleshooting and process stabilization are critical to success. Real-time data analysis and diagnostic tools play a key role in enabling operations teams to manage process variations and mitigate potential issues.

This presentation explores how advanced process data analysis tools were used to drive and support process optimization, contributing to the successful start-up of a new stock preparation plant ahead of the commissioning of a new DS Smith paper machine in Porcari (Lucca), Italy.