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In case you missed it, we are featured in the last issue of International Paper Board!

The article tells about a particular application of our air-cooled multidisc brakes installed at one of our clients, Italian leader in the paper, corrugated and packaging industry.

Read the full article to learn more about the potential of this technology, designed to improve unwinding efficiency, reduce maintenance and ensure maximum performance.

If you ask Renova engineers, the answer is yes! And they say they have the proofs, thanks to a loyal customer who has allowed testing in his plant for almost 10 years!

About Renova

Renova srl is an Italian industrial manufacturing company based in Milan.

It provides industrial solutions 100% designed and made in Italy for manufacturers and end users in the paper, paperboard and converting industry. Brakes, chucks, control systems and material handling equipment… Renova operates wherever there is a roll to unwind, rewind or move within the production plant.

About the client

This case-study focuses on a manufacturer based in Northern Italy, with 11 plants, 14 production lines and with around 120 years of experience in the paper, corrugated and packaging industry.

Their high-quality production starts with their pulp lines, passing through paper mills, corrugator lines, printing and box factories: each product is crafted with careful attention in providing the highest quality standards on the market.

Until 2013 Renova’s client was using monodisc brakes on its lines. Pads needed to be changed every 6 months, with a cost between 400-600€ for each brake.

They had continuous maintenance requirements, high air consumption and overall high costs.

Renova convinced the client to try Turborex, pneumatic air-cooled multidisc brake, on the 3300-width corrugator in the main Italian plant.

“Our old braking system required us to replace the pads every 6 months on each brake, for a total of 20 brakes on a single line of corrugators. Downtime, maintenance procedures and costs were a problem for us until we installed Turborex, and we managed to forget them for many years. For this reason, we have decided to update all our roll stands with Turborex brakes. Furthermore, if a brake requires maintenance, it only takes 10 minutes to replace the pad kit. Other advantages are that the Turborex multi-disc brake improves unwinding efficiency ensuring maximum performance: thanks to the double ventilation of the fan, Turborex operates at lower temperatures in the most demanding applications -24 / 7- where the working conditions are extreme. Over time, we have updated all roll stands with the Turborex.” The customer said.

After years of collected data, Renova can share the proven results of this application.

• Pad life: from 6 months to 7 years (pads were changed for the first time in 2020)
• Maintenance downtime: from 30 minutes to 10 per each brake;
• Air consumption completely eliminated, with no more rust on the brakes
• Maintenance requirements: only for ordinary cleaning operations
• Powders: Harmful emissions: reduced by 50% compared to single pad brakes
• Costs: at least 5600€ saved per brake (14 pad changed at 400€ each)
• Satisfaction: the client is 100% satisfied

Following the success of Turborex, the customer wanted to test other patented Renova technologies, as he was using core chucks, that required high maintenance and continuous replacement of parts.

“In addition, we have updated the old chuck with Renova’s Duplex, the roll ejector chuck. This have solved two long-standing problems that often occurred during the production cycle.

The first is the waste of paper, caused by the slipping of the reel core on the chuck. Our paper waste occurred most often because of an incomplete unwinding of the roll, during splicing or due to core damage. The second problem concerned a low safety level for the operators and damage to the machine, due to the manual intervention with levers or other tools for the discharged of stuck rolls or cores from the roll stand.”

Thanks to this installation the client:

• Costs: reduced maintenance components, no more parts to change
• Maintenance time: saved maintenance time;
• Safety: increased safety due to the elimination of manual intervention to unload the core;
• End-of-roll waste: Duplex uses paper rolls up to the last centimeters;
• Slippage: Duplex has a better grip from the first processing

In 2022 the client has decided to upgrade the Turborex brakes in his plant with the High Dissipation models.

The new HD discs with self-ventilation system guarantee a better performance as they improve the internal cooling capacity of the discs by quickly conveying the hot air to the outside.

In addition, the reduced discs diameter of 180 mm means 30% less distance covered and sliding speed of the friction materials with the discs for a substantial reduction of the pad wear and dust emissions in the working environment.

The Customer continues: “We like to work together with Renova. Entering into a partnership with Renova was the right decision, and this has given us a number of advantages that we didn’t even think possible before. It’s always advantageous to receive high quality, innovative solutions that increase productivity and safety in the plant while reducing production and maintenance costs.”