Tissue Converting machines by Movingfluid

In this article:

• What it is and how it works the “all-in-one” machine
• A Tissue Converting machine with exceptional performance
• Other practical advantages
• A unique solution, in every sense

Zero waste with Movingfluid’s automated systems for Tissue Converting

Advanced, automated, efficient: the Tissue Converting industry is among the most technologically advanced manufacturing sectors. Yet, there is one stage in the production line that is often overlooked, with potentially disastrous ripple effects on resource consumption, product quality, and overall business economics. 

We’re talking about the operations that take place before paper lamination: glue mixing, optional coloring, and filtration. These are critical steps that, surprisingly, are still performed manually, even in the most cutting-edge facilities.

It’s a significant gap that our team of specialized engineers has addressed by developing three systems capable of performing all these functions automatically, mechanically, and with full customization. 

These three kits can be supplied separately or delivered as a fully integrated, modular solution within a single machine capable of managing all three operations through one centralized PLC (Programmable Logic Controller). This “all-in-one” system saves both time and money, while consistently delivering optimal results thanks to the system’s pinpoint precision. 

What it is and how it works the “all-in-one” machine

What happens when the efficiency of SUPERSIX, Movingfluid’s machine for mixing the glue, meets COLORMIX, the smart solution for glue colouring in tissue paper production?
You get a complete system that eliminates the need for the most burdensome and expensive manual operations, and cuts waste to zero. 

In addition to the Movingfluid technology – born from years of experience of our Sfigasolver – a high-performance filter is added, which allows to recover 100% of the still usable glue completely cleaning it of impurities.

Here’s how the “all-in-one” machine works in detail. 

Glue dilution: a technical and operational revolution

Forget everything you’ve ever known, and probably even done, until now, because Movingfluid has long since solved the problem of manual dilution. No more operators carrying the tank from one point of the plant to another, goodbye manual measurement (or even worse, “by eye”!), no more product residue in the tank on the machine and defective paper at the outlet.

Our device fully automates glue mixing: the operator only needs to enter the desired dilution ratio into the PLC (where up to 100 different recipes can be stored) and start the cycle. The machine, equipped with a 100-litre mixing and dilution tank, takes only the necessary quantities of glue and water and creates the correct formula, accurate to the millilitre, without risks and without waste.

But preparing the mixture is not enough. You have to send it from the mixing tank to the one on board the machine from which it is taken for lamination. How is this transition managed? With maximum freedom: the operator can be left with the task of cyclically checking the destination tank and recalling the ready glue through a manual valve. Or, you can install an automatic sensor which detects the full level in the company tank and sends a signal to the mixing tank for the transfer of the preparation.  

Colouring: only if and when needed

Even the glue colouring can be entrusted, with the same advantages, to the Movingfluid Tissue Converting machine. The system in fact allows to mix liquid ink in a predefined percentage with glue, without complex manual interventions. 

The operator simply needs to operate a valve to divert the neutral glue from the ink dispenser: a quick process that takes just a few seconds and immediately makes the desired amount of coloured glue available. If the valve is not operated – or when normal circulation is restored – the system injects neutral glue without contamination or interruptions. 

Filtration: maximum optimisation

Impeccable dosage and efficient colouring might have been sufficient goals for others, but not for us. For this reason we have added an additional element, fundamental to guarantee real savings in terms of consumption and therefore costs: the filter. This automatic process replaces manual cleaning, often carried out with coarse and inadequate tools, thus reducing waste and disposal costs.   

The filter works continuously within the closed circuit and, as the glue returns from the ply lamination machine, perfectly separates the glue from paper fibres and other impurities produced by high-speed lamination. How? Thanks to a double step:   

1. A metal basket with 380 micron sheets intercepts the dirt by retaining the solid residues inside, while the cleaned glue flows out to return to circulation;  
2. When the filter is dirty, the system detects the level reached via the pressure switch and activates a cleaning plunger, discharging the dirt into a recovery tank. This tank contains an additional bag filter which further separates the dirt from the good glue, which is recovered and recirculated through a pump. 

Double filtration completely eliminates waste, of product and money, and improves the safety of operations. Personnel only needs to empty the filter tank when it is full.   

A Tissue Converting machine with exceptional performance

Compact and integrable with any other system already present, the Movingfluid’s “all-in-one” machine has unique features and advantages on the market, especially because it combines multiple manual functions together or still completely absent within the tissue industries:  

• The system is completely automatic, therefore no operator is required for its management;  

• Quality is constant over time: there are no errors and machine downtime;  

• Only the amount of glue needed for use is prepared, therefore neither too much nor too little; 

• The production or colour changes are almost immediate, because in just a few minutes you can switch from neutral to coloured glue and vice versa;  

• The order and cleanliness within the production department are greater because no equipment is required for manual preparation.  

All this entails a saving of time and money during all stages of processing: fewer operators means lower costs, fewer errors means lower costs, less waste means lower costs, fewer production downtimes means lower costs, less mess.

We don’t need to add anything else, do we?

Measurable savings thanks to ROI calculation

A concrete saving, which can be easily calculated thanks to our consumption matrix, specifically designed to translate the benefits of this solution into cash. Thanks to this tool, in fact, it is possible to make a realistic return forecast on investment, and therefore money saved (or “earned” in a certain sense), if you adopt the Movingfluid paper lamination system.

From experience, those who adopt our automatic dilution system obtain significant economic savings which contribute to the return on investment in approximately 12 months.  

Other practical advantages

Not only benefits for the wallet, but also for operations. Because with Movingfluid nothing is left to chance.  

The proof is in the extremely fast installation times, from order to commissioning, with the possibility of activating the machine using the remote technical assistance. Not only that: even if the system is already supplied with complete software it is always possible to modify or customise PLC functions based on specific needs.

The machine can also provide precise data on glue and water consumption for each batch of production. Valuable data that can be easily transposed into an Excel file to track costs, perform statistical analyses and make informed decisions on the profitability of different production lines.  

A unique solution, in every sense

Although there are already partial solutions for mixing and filtering glue on the market, no machine integrates all three functions (mixing, automatic colouring and filtration) as Movingfluid’s “all-in-one” machine.

And this is not the only unique factor of the devices supplied by Movingfluid. What sets us apart is our problem-solving and, above all, analytical approach. We know well that to solve a bad luck it is first necessary to understand it, for this reason we listen carefully to our customers and look for the most suitable solution to their problem.

This is a phase we continue to pursue, to gather feedback and continue improving: this is how, over time, we have adjusted the size of our machines – now even more compact – to meet the space requirements of the companies that use them.  

By systematising each individual challenge, we transform individual solutions into new opportunities for the entire market.   

If you want to improve your lamination automation process, cutting waste and consumption, there’s only one way to do it: contact us!

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