From Tissue machine to converting line: mastering dust handling with Valmet DustControl
In the tissue sector, rising production speeds, increasing product complexity, new fiber types and a stronger focus on sustainability goals are creating new challenges for effective dust management in converting lines. Dust accumulation is a critical issue that not only compromises the quality of finished products, but also represents a source of discomfort for operators and threatens operational continuity. To meet the specific production requirements for dust handling in tissue converting machines Valmet can now present a complete, modular, customizable, and high-efficiency solution: Valmet DustControl, designed to be integrated fully with Valmet machines and line control systems. The system is a proven solution made for tissue machines which has been further developed for converting lines, where efficient dust handling capabilities can be utilized.
Tailored technology for a cleaner converting
Valmet DustControl for tissue converting machines delivers measurable benefits in terms of performance, safety, reliability and the reduction of energy consumption. The system adapts to the characteristics of each production asset and uses specially developed suction modules for converting to effectively capture and remove airborne particles and dust from critical areas. In this regard, Valmet’s tailored solutions improve the overall working environment, reduce downtime for cleaning, and help maintain high hygiene and production standards. Effective dust reduction also lowers the risk of fires caused by potentially hazardous accumulations, enhancing overall plant safety and facilitating maintenance. An additional advantage is the ability to recover filtered air from the suction system, which is recirculated into the facility, thereby reducing energy consumption related to environmental climate control.
Maximum performances without comprimeses
The system is entirely designed to ensure maximum performance with the lowest maintenance effort, facilitated by the specially designed suction hoods located both on the machine and on the ground. Studies carried out on suction boxes, air ducts and filtration systems make it possible to create systems tailored to the machine needs and its actual operating conditions, limiting the power absorbed to the needed amount. The system is equipped with all the necessary precautions to ensure safe, long-lasting and, above all, simple operation. Control of the functions and status of the system is integrated into the machine logics and the main operator panel, allowing operators to always have an eye on the situation and be able to adapt the operating parameters to the current state of the production line.
Valmet has developed a configuration matrix that helps clients choose the most suitable solution in terms of suction capacity, number of hoods and emission levels. Two stack emission options are available: a standard setup, up to 10 mg/m³, and an advanced one, below 2 mg/m³. In some countries the latter enables the filtered air to be recirculated into the production environment, reducing climate control costs.
The Digital Heart of the Line: Real-Time Data and Remote Support
The collection of I/O signals from both the in-line and off-line sections of the system, integrated into the converting line’s PLC, allows centralized control through the machine operator panel. This enables operators to manage all functions more intuitively and efficiently, reducing response times and simplifying daily operations. It also allows for the creation of product- and process-specific control logic, with a strong focus on efficiency and energy consumption. Advanced diagnostic functions, combined with remote access by experts from the Valmet Performance Center, enable continuous monitoring, real-time process parameter analysis and immediate corrective actions.
With Valmet DustControl for tissue converting machines, we aim to reinforce our commitment to delivering integrated, sustainable and high-performance solutions designed to concretely address the challenges of tissue converting.” He concludes: “The system combines modular configurations with real-time monitoring of process parameters, enabling preventive maintenance strategies. This approach not only improves overall system visibility but also enhances overall reliability and accelerates the shift towards more digitalized production models.
