An existing plant represents significant technical and productive capital. But over time, even a well-designed line can become outdated or no longer competitive with current market standards. When operating costs increase, product quality becomes unstable or no longer meets market needs, or productivity declines, it is time to consider a targeted rebuild.
EilReplus offers a comprehensive revamping and rebuild service, designed to enhance the value of existing assets through customized, engineered upgrades. Our approach is based on detailed technical analysis: we carry out inspections, verify the condition of mechanical sections, electrical installations, and aerothermal systems, analyzing key indicators such as energy efficiency, pressing performance, drying capacity, and process stability.
Depending on results, we define three levels of intervention, each highly customized:
Partial or total rebuilds of single sections such as:
- Mechanical upgrades;
- Integration with new DCS systems;
- Modernization of stock preparation and machine approach systems to make them more efficient and versatile;
- Conversion of obsolete forming sections (flat wire tables, suction boxes, twin-wire) into Crescent Former technology;
- Press section modifications to maximize water removal efficiency;
- Replacement of cast iron Yankee cylinders with latest-generation high-efficiency steel Yankees;
- Optimization or modification of aerothermal plants with integration of heat recovery systems;
- Tail threading and reel change improvements;
- Replacement of obsolete rewinders with latest-generation models;
- Complete rebuilds of aged plants, restoring them to competitive performance levels compared to new plants, at a lower cost than a full greenfield investment.
Each proposal is supported by a techno-economic simulation and downtime estimates. Design, implementation, installation, and commissioning are managed directly by EilReplus experts, ensuring perfect integration of new and existing parts and thorough operator training.
Choosing a rebuild with EilReplus means giving new life to a plant, transforming it from a weak point into a strategic asset. A concrete way to increase competitiveness without discarding what still works.
