Paper presented at Go Wipes 18 about newest trends for a modern wet wipes manufacturing shopfloor. From Teknoweb Converting experience and lates installations.

1. Guido Conio
Chief Commercial Officier
g.conio@teknowebconverting.com
New trends in modern shopfloor for baby and household wipes
16th Nov 2018

2. • Leader supplier of advanced solutions to manufacture wet wipes
• Part of IMA group, Italian public company listed at Milan Stock Exchange,
43 manufacturing site all over the world, +1.5B Euro 2017 revenues

3. S t a t e O f C o n t r o l
Quick Change Over Raw Material Usage
Low Manning
Operations
Speed

4. • Modern shopfloors need to
quickly change products to satisfy
demanding requests
• Timely
• With minimum stop
• Time for change over depends on
• Reproducible settings
• Cleaning duration
Quick change over

5. Reproducible
settings
Rulers, gauges and tools to find
machine centerline at the first shot
and with no mistake.
Reproducible settings

6. Extensive use of automation to retrieve
machine setting by HMI
Objective is to have machine completely set up
during cleaning time and able to start over
without any additional delay.

7. CIP procedures embedded in the machine PLC
to perform proper sequence and ensure its
execution in the shortest possible time
Optimimum CIP and COP combination to
parallelize operations
Use of automatic devices to perform CIP
quickly and effectively
Sanitary design is a must
Shrinking cleaning time

8. Small footprint
High throughput with
minimum waste
Capability to use
newest raw materials
Low manning
- Less training
- Less hassles
- Less cost

9. 200 packs/min line
Footprint
Count Clips x pack Packs/min
48 4 200
60 5 180
72 6 150

10. RDC
Short vs long line
80 sheets pack
STACKER
The perfect equipment for the agile manufacturing
SAW
Faster setting, less manning,
quick cleaning
¼ rejects for splices
VS

11. Producing 40 m/packs - Solution comparison
• High speed (200 ppm) – High
efficient solution
– Total product cost (including line
cost) = 0,321 Euro/pack
– Capital investment is 1.4 M Euro
– Efficiency 90%
– Waste rate 2%
– MUT 99%
Profit 5.15 M Euro per year
• Medium speed (110 ppm) –
Medium waste (2 lines needed)
– Total product cost (including line
cost) = 0,341 Euro/pack
– Capital investment is 0.5 x 2 = 1M
Euro
– Efficiency 80%
– Waste rate 5%
– MUT 98%
Profit 4.35 M Euro per year
Since day 1 HI-Speed machine makes 800k Euro more profit
Simulation takes into account capital investment
This doesn’t consider all added values of better sanitary design, lower contamination risks, better quality etc etc

12. All contents are property of Teknoweb Converting and cannot be reproduced without explicit consent
Simulation details
Teknoweb NEXT20+2 GenPack
Line Saturation 0% 15% 30% 45% 60% 75% 90% 66%
Speed (ppm) 200 200 200 200 200 200 200 200
Efficency Rate (%) 90% 90% 90% 90% 90% 90% 90% 90%
Waste Rate (%) 2,0% 2,0% 2,0% 2,0% 2,0% 2,0% 2,0% 2,0%
Change Over Time (h) 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5
Change over per week (n) 10 10 10 10 10 10 10 10
Manpower (n) 2 2 2 2 2 2 2 2
Manhour cost (€) 10 10 10 10 10 10 10 10
Maintenance Time (h/week) 2 2 2 2 2 2 2 2
MUT (%) material utilization 99% 99% 99% 99% 99% 99% 99% 99%
Production shifts per day (n) 3 3 3 3 3 3 3 3
Net Raw Material (€/pack) 0,30 0,30 0,30 0,30 0,30 0,30 0,30 0,30
Power Consuption (kW) 30 30 30 30 30 30 30 30
kwh cost (€) 0,15 0,15 0,15 0,15 0,15 0,15 0,15 0,15
Floor space cost per m2 (€/month) 5 5 5 5 5 5 5 5
Floor space needed (m2) 1000 1000 1000 1000 1000 1000 1000 1000
Line Price (K€) 1.400 1.400 1.400 1.400 1.400 1.400 1.400 1.400
Amortization Time (Y) 5 5 5 5 5 5 5 5
Product selling price (€/pad) 0,45 0,45 0,45 0,45 0,45 0,45 0,45 0,45
Yearly Figures
Yearly net production (M) - 9,1 18,3 27,4 36,5 45,7 54,8 40,0
Yearly culled products (M) - 0,20 0,41 0,61 0,81 1,01 1,22 0,89
Production time per year (h) 0 900 1800 2700 3600 4500 5400 3942,906711
Gross raw material cost (€/pack) 0,303 0,303 0,303 0,303 0,303 0,303 0,303 0,303
Raw material - 2.766.764 5.533.527 8.300.291 11.067.055 13.833.818 16.600.582 12.121.212
Labour - 18.000 36.000 54.000 72.000 90.000 108.000 78.858
Waste - 61.484 122.967 184.451 245.935 307.418 368.902 269.360
Energy - 4.050 8.100 12.150 16.200 20.250 24.300 17.743
Space 60.000 60.000 60.000 60.000 60.000 60.000 60.000 60.000
Line 280.000 280.000 280.000 280.000 280.000 280.000 280.000 280.000
Mantainance+Update - 10.000 12.000 13.000 15.000 16.000 18.000 20.000
Total costs (€) 340.000 3.200.297 6.052.595 8.903.892 11.756.189 14.607.486 17.459.784 12.847.174
Total cost per pack (€) #DIV/0! 0,351 0,331 0,325 0,322 0,320 0,319 0,321
Gross revenues (€) - 4.108.644 8.217.288 12.325.932 16.434.576 20.543.220 24.651.864 18.000.000
Gross profits (€) - 340.000 908.347 2.164.693 3.422.040 4.678.387 5.935.734 7.192.080 5.152.826
Competitor 110 ppm + 1 FP
Line Saturation 0% 15% 30% 45% 60% 75% 90% 70%
Speed (ppm) 110 110 110 110 110 110 110 110
Efficency Rate (%) 80% 80% 80% 80% 80% 80% 80% 80%
Waste Rate (%) 5,0% 5,0% 5,0% 5,0% 5,0% 5,0% 5,0% 5,0%
Change Over Time (h) 1 1 1 1 1 1 1 1
Change over per week (n) 10 10 10 10 10 10 10 10
Manpower (n) 3 3 3 3 3 3 3 3
Manhour cost (€) 10 10 10 10 10 10 10 10
Maintenance Time (h/week) 2 2 2 2 2 2 2 2
MUT (%) material utilization 98% 98% 98% 98% 98% 98% 98% 98%
Production shifts per day (n) 3 3 3 3 3 3 3 3
Net Raw Material (€/pack) 0,30 0,30 0,30 0,30 0,30 0,30 0,30 0,30
Power Consuption (kW) 20 20 20 20 20 20 20 20
kwh cost (€) 0,15 0,15 0,15 0,15 0,15 0,15 0,15 0,15
Floor space cost per m2 (€/month) 5 5 5 5 5 5 5 5
Floor space needed (m2) 1000 1000 1000 1000 1000 1000 1000 1000
Line Price (K€) 500 500 500 500 500 500 500 500
Amortization Time (Y) 5 5 5 5 5 5 5 5
Product selling price (€/pad) 0,45 0,45 0,45 0,45 0,45 0,45 0,45 0,45
Yearly Figures
Yearly net production (M) - 4,3 8,5 12,8 17,0 21,3 25,5 20,0
Yearly culled products (M) - 0,27 0,53 0,80 1,06 1,33 1,60 1,25
Production time per year (h) 0 900 1800 2700 3600 4500 5400 4227,54329
Gross raw material cost (€/pack) 0,306 0,306 0,306 0,306 0,306 0,306 0,306 0,306
Raw material - 1.303.406 2.606.811 3.910.217 5.213.623 6.517.029 7.820.434 6.122.449
Labour - 27.000 54.000 81.000 108.000 135.000 162.000 126.826
Waste - 81.463 162.926 244.389 325.851 407.314 488.777 382.653
Energy - 2.700 5.400 8.100 10.800 13.500 16.200 12.683
Space 60.000 60.000 60.000 60.000 60.000 60.000 60.000 60.000
Line 100.000 100.000 100.000 100.000 100.000 100.000 100.000 100.000
Mantainance+Update - 10.000 12.000 13.000 15.000 16.000 18.000 20.000
Total costs (€) 160.000 1.584.569 3.001.137 4.416.706 5.833.274 7.248.843 8.665.411 6.824.611
Total cost per pack (€) #DIV/0! 0,372 0,352 0,346 0,343 0,340 0,339 0,341
Gross revenues (€) - 1.916.006 3.832.013 5.748.019 7.664.026 9.580.032 11.496.038 9.000.000
Gross profits (€) - 160.000 331.438 830.876 1.331.313 1.830.751 2.331.189 2.830.627 2.175.389
200 ppm line 110 ppm line

13. Reduced manning
Automation and supporting tools allow
less operators to manage a full line
Teknoweb NEXT requires only 1-2 operators
to run a complete 200 packs/min production
line
Stable machine allows operators to monitor
and perform supervision tasks (quality
checks, process overview)

14. • Modern machines must use all
raw materials effectively and
rejecting the real minimum
• Consistently
• It makes a huge impact to the
bottom line.

15. • Cost of raw material rejected during operation is BY FAR
the most important and overwhelm any other operational
cost (including equipment cost).
• A 200 packs/min line uses 12M Euro raw material per
year (as average). Just 2% less rejects (compared to
any standard line) means 240.000 Euro saved yearly.
• In 3/5 years you repay complete line cost!
Raw Material Usage

16. High Speed LAP
Unwinder
Single or double rolls unwinders
Controlled rolls (not free to rotate)
LAP splice with no tail
Splice at zero speed
Slow acceleration after splice
Web accumulator + tension control
Allow high inertia rolls (1.5m)
Suitable for flushable

17. LAP
FLYING
√
√
√
√ √ √
X X X X X
X X X
Tail < 300 mm
LAP vs Flying

18. All contents are property of Teknoweb Converting and cannot be reproduced without explicit consent

19. LAP vs FLYING
Refilling 20 lanes folder
LAP (double reel splice – Teknoweb technology)
FLYING
20 wipes/clip x 5 rejects x 20 splices = 2000 wipes x 0,170 m = 340 m
20 wipes/clip x 3 rejects x 10 splices = 600 wipes x 0,170 m = 102 m
Left over 3 m/reel 20x3 = 60 m
Total rejects = 162 m
- 52% REJECTS vs FLYING SPLICE

20. • Use shortest line when consumer allows it (more
dropouts in interfolded)
– 25 lanes rejects half of 50 lanes
– 12 lanes rejects half of 25 lanes
• Use most effective splice technology
– LAP vs flying splice
– Multiple lanes vs individual lane splice
Ways to reduce rejects

21. State of control
• Centerline as tool to deliver quality consistently
• No reasons for adjustments based on operator’s
«sensibility»
• Product would be reproduced consistently if production
line is set strictly according to centerline
Modern shopfloor should be based on machines in state of process control

22. All contents are property of Teknoweb Converting and cannot be reproduced without explicit consent
Takeaway
• Modern shopfloor is based on
– Low manning
– Short and fast production lines
– With a full sanitary design
– Able to handle the most difficult flushable material
– With unwinding technology able to control substrate tension
– And reduce splice rejects to the minimum

23. Thank You
To know more about data and technology used in this presentation send an email to
sales@teknowebconverting.com