PERFECTING PAPER

The Mill Group’s plant will be the most advanced and green in the Western Hemisphere. Inside the mill’s optimized location, it performs three main processes: Parent Roll Production, Converting and Embossing, and Wrapping and Packaging.

The Mill Group’s 600,000 square foot facility is planned to be located centrally within 700-1000 miles of 52-56 % of the U.S. population.

The evaluated venue options will provide Mill Group’s customers with shipping savings and short delivery times.

Mill Group’s US facility will have no comparable competitors with its all-new and state-of-the-art manufacturing equipment. Our innovative manufacturing model creates extreme efficiency, maximizes size, employs a flat organizational chart, and delivers effortless vertical integration. Mill Group’s design allows one mill, in one location, to produce finished goods starting with only raw materials.

Parent Roll

The equipment selected to produce the parent rolls for the Mill Group is Toscotec’s AHEAD 2.2S. As a company, Toscotec is so revered that in December 2019, 90% of Toscotec stock was purchased by a pinnacle of the tissue paper industry, the Voith Group.

Each parent roll is nine feet tall and weighs 2000 pounds. The mill will be utilizing two Toscotec Ahead 2.2S Tissue Machines for parent roll production. The Ahead 2.2S is the largest crescent former tissue machine Toscotec makes for standard-length parent rolls. These massive machines are over a football field(100 meters) in length, 150 feet wide (45.5 meters), and four stories high (12.5 meters).

The refined wood pulp (i.e., the raw material) is fed into the Toscotecs, where water is removed as it travels by the vast 16 foot yankee dryer. The paper speeds through the Toscotec’s at 60 miles per hour. The pulp is processed into parent rolls at a rate of 8 per hour. These large parent rolls are then refined by a converting line to produce the single rolls of toilet tissue and paper towels we use in our homes.

Converting Line

Converting lines take the one-ton parent rolls and transform them into over 5,000 individual bath tissue(toilet tissue) rolls or 4,000 kitchen roll towel(paper towels) rolls. The Mill Group’s converting line is a new and, again, state-of-the-art high-speed mechanism. Here the parent rolls are transformed into toilet tissue and paper towels at a speed of 30 miles per hour.

The Parent Roll is first unwound by the “Unwinders” and fed into the “Embosser.” Here, the standard or clients’ custom message is embossed onto the paper product. The custom messages are a Mill Group specialty as we can perform the service for virtually the same cost as a standard image. Then the paper is wound into thinner rolls, called “logs” that remain 9’ long. Finally, these enter the “Log Saw,” where a large 3’ circular blade cuts the 9’ logs into finished individual toilet tissue or paper towel rolls.

Wrapping and Packaging

Now the single rolls of bath and kitchen roll towels must be wrapped and packaged for shipping. The Earth Mill Converting Line will be paired with a specifically designed, fully automated Stax Technologies high-speed packaging line.
This optimized system has both multi-pack and individual packaging ability. The design of Stax’s packaging line provides flexibility and production capability. The system is excellent for both the At Home Market and the Away From Home Market. The line features two Stax Dinamica single roll machines and one Ultima multi-packer with Rockwell Automation. The system can wrap, box, palletize, and load over 1,800,000 bath tissue rolls every 24 hours.