Softer and more efficient? In tissue production, this combination is often seen as incompatible. When the crepe ratio decreases or machine speed increases, product quality typically suffers particularly elongation, strength, and perceived softness. As a result, many machines are intentionally operated below their true efficiency potential to protect quality.
The Yankee cylinder is the central point where efficiency and quality are determined. The Yankee coating on the surface plays a decisive role in how the sheet is creped. Industrial short‑ and long‑term trials show that with the right Yankee coating system, the traditional trade‑off between product quality and operational efficiency can be eliminated. In this regard, PETROFER’s COTAC 3240 H demonstrates outstanding performance.
Case Study
A European tissue producer operates a high‑performance tissue machine. Up to now, the machine was run below its maximum efficiency because lower crepe levels resulted in losses in sheet elongation.
During an industrial trial, the existing Yankee base coating was replaced with COTAC 3240 H from PETROFER. This allowed the crepe ratio for toilet tissue to be reduced from 21 – 23 % down to 19 %, and for towel grades down to 18 %. Elongation remained stable at 16.5 – 18 %, depending on product and basis weight, while both MD and CD strength stayed constant. As a result, productivity increased by +2 % for towel grades and +3 % for toilet tissue.
Alongside improved production efficiency, another highly relevant economic effect was observed: the dosage of the base coating chemical could be reduced by around 50 % from approximately 61 ml/min to about 30 ml/min when using COTAC 3240 H. Despite this significant reduction, coating stability, doctor blade life, and Yankee protection remained consistently high. At the same time, the machine benefited from reduced dust formation and improved heat transfer, further enhancing process stability.
Conclusion
Industrial results clearly demonstrate that higher production efficiency and stable product quality are not contradictory. With COTAC 3240 H from PETROFER, crepe ratios can be reduced, productivity increased, and chemical costs lowered all without compromising quality.
