The traditional systems for heating embossing rolls using piping with hot oil or pressurized water, or with heating elements, use up large amounts of energy, have high heat dissipation, and are underperforming.
"The heating systems used so far in production," comments Eng. Andrea Gambini, Global Research & Development Director of Körber Business Area Tissue, "are now too underperforming: heating the embossing roll by means of a hot liquid flowing inside it requires a high use of energy, as does trying to heat it with heating system with resistors. Oil systems require dedicated facilities to heat and recirculate large masses of oil, greatly impacting the environment and creating unsustainable conditions. In addition, these factors contribute to lower overall equipment efficiency (OEE)."
The tissue market is constantly evolving," says Eng. Gambini, "and with it comes the need to offer more effective, efficient, sustainable and user-friendly solutions. Safety, simplicity, flexibility and efficiency: these are the cornerstones on which the Warm-up Contactless Double system is likewise based. It will be presented at iT's Tissue 2022 on the in-phase DESL (Double Embosser Synchronizer Lamination) product and it will be possible to have a tangible example of how it works and how easy it is to integrate into the new 456AX embosser to achieve maximum production efficiency. And now that induction heating is finally double, all the benefits are also doubled.
"Our Warm-up Contactless system," says Eng. Gambini, "heats the embossing rolls from the outside without any physical contact with the rolls themselves and reduces heating times by 1/3, resulting in energy savings of more than 60%. This system can be used with any existing engraved rolls and is designed not to interfere with the operator's work." These features combine to show how state-of-the-art is the Warm-up Contactless system and demonstrate how Körber Business Area Tissue cares about sustainability.
"Building on our experience in the tissue industry, with the desire to innovate by offering our customers more innovative technological solutions, our R&D center has further advanced Warm-up Contactless by expanding our product portfolio with the double embossing system, which retains all the advantages of the solution already on the market, and allows it to be used in the production of kitchen towels as well," concludes Eng. Gambini.