Cellyne is in the midst of installing a second tissue machine at its Haines City, FL, plant and fully expects to repeat the success it has had with its first
October 2008
By Felicia Willis, Associate Editor, Pulp & Paper magazine, RISI
When Pulp & Paper last checked in on independent tissue converter Cellynne, it had started a new tissue machine. Now the second machine is being installed with high hopes for its success as well.
Central Florida, the home of Disney World, Universal Studios and SeaWorld also shares this address with paper manufacturer, Cellynne, Corp. Cellynne is relatively new to tissuemaking, but has done a phenomenal job of playing its position in the North American tissue market.
Cellynne is a fully integrated paper manufacturer. The company was founded in 1988 and is currently a leading supplier of quality bath tissue and towel products for both at home (AH) and away from home (AfH) markets. In addition to its corporate office in Haines City, FL, site where the company also converts 65% of its production, there are converting facilities in Las Vegas, NV, (15%) and Green Bay, WI, (20%).
In 2006, Cellynne launched operations at the high-tech paper mill, marking its evolution from paper converter to full-service manufacturer. The expansive, multi-million dollar facility has enabled the company to improve the quality of its paper products and reinforce its reputation as a reliable towel and tissue supplier.
The products are shipped nationwide but more specifically, the markets are close to each plant. Haines City ships 90% of products made to the southeast, Green Bay to the midwest and Las Vegas to the southwest in the US.
Cellynne has high expectations for the new tissue machine, and fully expects to start up on schedule. In the August 2006 issue of Pulp & Paper, one of the founders and vice president of Cellynne, Marc Allegre, predicted, “Within two years, Cellynne will look to construct ‘a sister building’ at the Haines City site to house a second paper machine.” That plan is now coming to fruition with a twin machine currently being installed. An addition to the building that house the two machines is under construction and the new machine will be up and running in January 2009. The second phase of this project is the installation of a deinking facility, which is scheduled to open at the end of 2009.
Of the new machine, Allegre, says, “It’s a twin machine of PM 1. It’s the exact same machine, with minor changes such an added dust control system, small changes in the engineering, changes in sheet handling and improvements with the headbox.
Cellynne’s DCT 100 tissue machine features the following:
• Width: 102-in. trim
• Max speed: 6,600 ft/min
• Length: 108 ft
• Height: 34 ft
• Capacity : 35,000 tons/yr
• SymFlo TIS headbox
• Crescent former
• Yankee dryer: 18-ft dia
It’s all in the timing
“Once PM1 was well underway, and we gained knowledge from that experience, we began planning for the second machine to be installed,” Allegre explains. “We are quite satisfied with the progress of the first machine.” “Once the second machine starts, PM 1 will become the dedicated machine for towel production and PM 2 will produce the 9- to 16-lb tissue grades. This will give a total manufacturing output of 70,000 tons/year”.
Cellynne’s location is definitely a benefit. It is only three miles from the water treatment facility that will provide water for the mill. In fact, it has one of the most closed water system in the US. One of the advantages of being so close is that Cellynne recycles 85-90% of the water used for the mill. Another plus is that Haines City is currently building a water pipeline for reclaimed water usage. Cellynne is working on an agreement with Haines City in regards to this pipeline that will prove beneficial for both Cellynne, and the city. The company will only use reclaimed water upon the completion of the pipeline.
Employees
Allegre finds that having twin machines is the best-case scenario. By already being familiar with the first machine, training new employees and getting the machine ready for start up will be less of a challenge. The full management crew from the first machine has been given the opportunity to extend their responsibilities, carrying over for the second machine as well. Plant Manager Jeff Hammonds and the PM 1 management team will cover the start up activities with the addition of Jerôme Bareth as the PM 2 Superintendant. “We are using PM1 as a training model, and started hiring operators for the startup of the PM 2,” Allegre said. “We hired people from other mills, and some from the community, as well.”
Cellynne employs approximately 300 employees - about 200 in Haines City, 50 in Green Bay and 50 in Las Vegas.
Focused on the future
All the raw materials used are outsourced, mainly from the Alabama River Pulp, and some from Brazil. Cellynne currently uses virgin fiber in combination with recycled pulp in order to achieve the quality standards requested by our customers. With the proposed installation of the de-inking plant, the mill will gain more flexibility with his fiber supply. Though still in the planning stages, the system will be installed adjacent to the tissue machines.
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