a gold eagle spread its wings an that empowers the future 2017/conference proce… · &...

A Gold Eagle Spread Its Wings‐An Innovation that Empowers the Future

Universal Paper Manufacturers' Greenfield Tissue Mill, South Africa Case Study

Presented by: Jonathan Sher Project Director [email protected]

Presented by: Maja Mejsner Director Business Development & Marketing – PMP [email protected]

Miami, Florida 6th October 2017

• UPP Insight

• UPM Tissue Adventure

• Gold Eagle Project Story

• Technology That Counts

• Summary – The Future Looks Bright

• Gold Eagle Today – Virtual Mill Tour

Introduction

• Country: South Africa• Population: 56 mln• Market Type: Emerging• Forecasted Market Growth: 5%

Per Year• Tissue Consumption : 4.8 kg Per

Capita (2014)• GDP per Capita: 5273 USD• Product Preferences: Toilet Paper

South Africa – Tissue Market

• UPP (Universal Paper & Plastics) –a Family Business Established In 1950

• A South African Tissue Manufacturer & Converter (Mill Location: Ga-Rankuwa Near Pretoria)

• Annual Turnover: $65 Million• Business Units: UPM (2008) &

Uinks (2002)• Values: Integrity, Commitment,

Empowerment, Excellence

UPP Insight

• Mission:

To Develop Innovative Products ForThe Most Demanding CustomersAdding Flavors of Creativity &Education.

• Vision

To Become The Proffered TissueSupplier in The South AfricanRegion, Offering A Wide Span ofUltra-Premium, 100% Virgin FibreTissue Paper Products.

UPM Mission & Vision

• Annual Capacity: 36 000 t/a (Covers 12% of A Local Market) – Ranked 3rd in South Africa

• Machine Fleet – (5) Units

• Focused on Branded Virgin Tissue Products, Parent Rolls and Water- Based Inks

• Tissue Products: Bathroom Tissue, Household Towels, Serviettes/Napkins, and Hankies

• FSC Certified

• Dermatologist Approved

UPM Fact & Figures

• UPP Insight




• Gold Eagle Today

• Summary – Future Looks Bright

Introduction

• 1950s-1990s – Various Paper & Plastic Products, specializing in Serviettes/Napkins

• 2006 – Invested in Roll Converting and entered roll market

• 2009 – UPM 4 Chinese Tissue Paper Machines Up & Running

• 2014 – Contract Signing for a Green Field Tissue Mill Project

• Feb 2017 – New Green Field Mill came on Stream (Gold Eagle Project)

UPM Tissue Adventure

• UPP Insight






Introduction

• Widen Product Portfolio (Adding Ultra-Premium Tissue)

• Improve Consistency and quality of The Final Product

• Lift Fleet Technology to A Higher Level

• Entering Undiscovered Market Niches (New Products In A Portfolio)

• Increase Market Share Via Capacity Increase (Double Current Annual Capacity)

Gold Eagle Project Goals

• From The Idea to The Significant Expansion Plan

• Learning Process & Facing New Challenges

• Reference Visits Around The Globe

• Contract Signed: December 2014

• Project Name - Gold Eagle (DrG. Goldstein & A National Symbol of Poland)

Gold Eagle Project Background

PMP (Paper Machinery Producer) At a Glance

• Global Provider of Tissue, Paper & Board Technology

• Polish-American Company• Annual Turnover (FY 2017:70 mln

EUR)• Over 160 Years of Experience (est.

1854)• Focused on Spectacular

Achievements • Flexible Partner With a Cultural

Sensitiveness

PMP MISSIONWith Passion & Pride, We Create Success TogetherIn The World Of Paper

PMP VISIONTo Be The Best Supplier of Advanced Technologies

• UPP Insight






Introduction

• Project: Green Field (New Production Facility)

• Location – Next To The Existing Facility

• 35 000 Square Meters (UPP)• 22 000 Square Meters (UPM) –

Project Gold Eagle• Scope of Supply: Turn-Key Delivery• Project Milestones:

• Civil Works Start: February 2015

• TM Erection Start: August 2016• TM Start-Up: February 2017

Mill Data

• Machine Type: Crescent Former (Intelli-Tissue® 1600 Advanced)

• Reel Trim: 105 inch (2670 mm)

• Grade: 13-40 gsm (Virgin Fibres)

• Operating Speed : 5250 fpm (1600 m/min)

• Capacity 28 000 tpa

TM5 Data

Technology That Helps

• Philosophy: Premium Quality & Reliability

• Tailored Made Solutions – A Unique Final Product

• Optimum Cost Solutions (PMPoland - Poland & PMP IB – China)

Gold Eagle Project Philosophy

• All Equipment Pre-Assembled

• FAT – Poland, Italy, China, Hungary

• Certified Materials

• A Wide Set of Movement Tests Completed

• PRINCE 2 – Project Management Approach

Gold Eagle Project PhilosophyTop Manufacturing Quality & Risk Management

• Intensive Training Prior to Start-Up

• TM Started Up Smoothly On 19th Feb 2017, 11:20 a.m. – Paper on Reel

• Babysitting – 5 Months Period

• Performance Protocol Signed April 2017

Start-Up & TM Optimization

Technology That HelpsUltra Low Media Consumption

• Media Consumption Figures (at 17.5 gsm):

• Steam: 2.3 T/T• Water: up to 6-7 m3 /T• Electricity: 800 kWh/T

(Entire Building)• TM Efficiency 95%

BENEFIT: ULTRA LOW MEDIA CONSUPTION –MORE MONEY IN THE POCKET

Technology That HelpsPremium Tissue Quality

• High bulk• MD/CD – 1:1.5 – 1:3• CD Basis Weight Profile: 2σ Less

Than 4 %• Moisture Profile: 2σ less than 3.5%• HF>90• Scrap – Less Than 2%

Samples available!

BENEFIT: PREMIUM TISSUE QUALITY – HIGHER MARGINS

Technology That HelpsUser-Friendliness of Equipment

• Annual Downtime: 18 days • Smart and User Proof Solutions –

TM Easy to Operate• Easy Cleaning – Comfortable

Access to Headbox/Press• Optimized Clothing Changes• 6 People To Operate The Line (60%

Savings on Employment)

Felt & Wire Change TimeWire Fabric (3 people) Up to 1 hour

BENEFIT: USER‐FRIENDLINESS OF EQUIPMENT –TIME SAVINGS

• UPP Insight






Introduction

• TM Is Flying (Running Full Speed) – 5 Months After Start-Up

• 1st State-Of-The-Art TM Installed in South Africa In The Last 20 Years

• The Biggest Project in UPM History (Taking Both Value & Scope Into Account)

• 1st PMP Project in Africa & 1st Turn-Key Tissue Mill

Gold Eagle Today

• The Current ROI - 8% -Expected to Reach 16% Once The Full Capacity Has Been Sold

• The Cost Per Ton Has Improved By 2% And Will Reduce By Up To 7% Once The Full Capacity Has Been Reached

• Quality & Capacity Targets Achieved

• The Future Looks Bright

Gold Eagle Summary

• Strong Relationship & True Partnership

• Mutual Respect

• Share Similar Ideas & Values

• Business Partners and Families

• Open Communication Channels

• Facing Challenges Together To Achieve A Lot More

Summary – Partnership As A Key For Success

• UPP Insight





• Gold Eagle Today –Virtual Mill Tour

Introduction

Join the Tour Now!

Gold Eagle Virtual Mill Tour

https://www.youtube.com/watch?v=pQ8qpo2nN6U&feature=youtu.be

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