Automation of Tissue Paper Material Flow at Eurovast

Eurovast, a producer of tissue paper products, has undertaken a comprehensive modernization of its manufacturing site in Pescia, Italy. The project involved transitioning from traditional production lines to a highly automated plant structure. This shift was designed to facilitate the end-to-end processing of tissue paper, starting from the initial loading of base paper rolls through to the final palletizing of finished goods.

Operational Challenges and Environmental Factors
The primary technical challenge at the Pescia facility was the requirement for continuous 24-hour operation while minimizing unscheduled machine downtime. In the tissue paper industry, the high volume of airborne paper dust serves as a significant cause of mechanical wear and system failure. Furthermore, the plant required a material flow system capable of handling complex routing to multiple packaging units without manual intervention or frequent maintenance pauses.

Selection of the Material Flow Solution
To address these requirements, the company selected the VarioFlow plus chain conveyor system. This solution was chosen for its modular design and its ability to be configured for complex production layouts. Technically, the system was preferred due to its resistance to dust accumulation, which is a critical factor in extending the service life of transport components in paper-heavy environments. The selection was also driven by the need for a system that could integrate with digital control software to manage product distribution.

Deployment and System Integration
The implementation involved the installation of an automated conveyor network that connects the unwinding stations with primary and secondary packaging machines. The deployment utilizes a software-controlled material flow that allows for the dynamic redirection of paper rolls based on the operational status of downstream equipment. This configuration ensures that the production line remains active even if specific packaging units are offline. The mechanical layout was optimized to reduce the total number of drive units, streamlining the physical footprint of the conveyor network.

Operational Results and Technical Benefits
The integration of the chain conveyor system has resulted in a significant reduction in mechanical failures related to dust ingestion. The design of the chain and tracks reduces friction, which, combined with the optimized number of drives, has led to a decrease in overall energy consumption. These technical improvements have lowered the total cost of ownership by reducing maintenance frequency and enhancing the reliability of the 24-hour production cycle. The automated material flow has eliminated the need for manual handling between processing phases, ensuring a consistent throughput across the facility.

Edited by an industrial journalist, Lekshman Ramdas, with AI assistance.

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