Efficiency Boost
ContiRoll® RETROFIT
Press Extension + Lightboard Package
Greater efficiency and a broader product portfolio - that's what Çamsan Entegre was looking for when they decided to modernize their MDF production line in Sakarya, Turkey. Prior to our plant upgrade, the Contiroll produced exclusively standard MDF panels. In just 41 days of downtime, the plant was extended by about 6.6 m with eight additional frames and equipped with new heating plates. In addition, the system was retrofitted with a lightweight panel package for MDF. As a result, Çamsan Entegre has expanded its product portfolio to include particularly resource-efficient panel variants with lower density, thereby further increasing its productivity. Once the work was completed, the line was able to resume production - five days ahead of schedule and with a capacity increase of nearly 15%.
Overview
The modernization in detail
- Extension of the ContiRoll® toward the press discharge with 8 additional frames (6.64 m) to a total length of 55.34 m
- Integration of the Lightboard package, including reconfiguration of the press cylinders and hydraulic adjustments
- Mechanical adjustments during final assembly and software modifications
- Installation of a measuring frame to permanently set the exact pressing distance (independent of temperature and vibration)
Insight
The retrofit in pictures
Photos: SLS / Çamsan Entegre
The modernized press
Photos: SLS
Interview
5 questions, 5 answers
An interview with Ömer Yavuz Bayrak, Production Manager at Çamsan Entegre in Sakarya
Why did you decide to invest in modernizing the press and what were your main objectives?
“When discussing this modernization project, we need to consider its two aspects separately—the press expansion on the one hand, and the modernization with the Lightboard Package for MDF on the other.
Regarding the press expansion, our goal was to achieve higher production volumes with the existing equipment through a manageable investment, thereby increasing the overall profitability of our existing production line. And we wanted to do this without additional staff and with reduced energy consumption per board produced. By retrofitting the system with the Lightboard Package, we can now produce a new product and expand our product range to include Lightboards. For us, this is a key prerequisite for tapping into new markets, which we are particularly aiming for in the export sector. Our overarching goal is to reduce the cost per board produced by minimizing personnel requirements and lowering energy consumption. Furthermore, we aim to generate additional growth momentum through the targeted expansion into new sales markets.”
What challenges did you face and what did you think went particularly well?
“In preparation for the modernization, we worked with Siempelkamp to draw up a comprehensive renovation and preparation plan. All resulting tasks were completed in advance based on this plan. Thanks to this excellent preparation and collaboration, the implementation proceeded smoothly. There were minor deviations from the plan here and there, but these did not cause any problems due to the high level of expertise and flexibility of all parties involved. The careful detailed planning prior to the renovation paid off and ensured a smooth implementation.”
What are the benefits of the modernized system?
“Here, we can truly list a whole range of benefits that we can realize through the plant renovation: We have increased production capacity, reduced unit costs, improvement of mechanical product properties, and expanded our product range—all of which serve as a foundation for tapping into new markets worldwide.”
How would you rate the collaboration with SLS on this project?
“The excellent collaboration with SLS laid the foundation for the successful completion of this extensive modernization project. We benefited greatly from the precise work plan we developed together, which was kept up to date throughout the renovation work. The planning was excellent and addressed tasks separately according to responsibility, ensuring maximum transparency and operational flexibility. The careful preparations were accompanied by regular meetings and on-site inspections. Our questions were always answered quickly and comprehensively, and the on-site support of experienced SLS specialists ensured the successful and smooth execution of the project.”
How would you summarize this project in one sentence and what happens now?
“The modernization we have carried out represents a cost-effective and efficient solution for us. Our next goal is to further optimize the production quality and unit costs of our press and ensure that the system operates at maximum capacity. In doing so, we are focusing our research and development efforts primarily on energy consumption and raw material costs.”