Tissue and nonwoven converters run high-speed rewinders converting large parent reels into dozens of finished roll formats simultaneously. Deckle Plus tracks parent reel consumption, enforces GSM sensitivity constraints, and minimizes trim across every rewinder shift.
Tissue paper parent reels are produced on high-speed machines and represent significant material cost. Converting parent reels into facial tissue packets, toilet rolls, and kitchen towels at the rewinder is where yield is won or lost. A 2% improvement in rewinder trim waste on a 30 t/day tissue converter can save $8,000–$12,000 per month, and most tissue plants have no optimization tool for rewinder planning.
A tissue and hygiene product manufacturer in Haridwar, Uttarakhand produced facial tissue (210mm rolls), toilet tissue (100mm rolls), and kitchen towel rolls (230mm) from a 2800mm parent reel rewinder. The plant ran three shifts and produced 28–32 tonnes per day across all formats.
The rewinder operator received a daily production schedule from the planning team: a handwritten sheet specifying which formats to run in what sequence. The schedule was prepared based on pending customer orders but without any mathematical optimization of the width combination. Typical trim waste ran 2.4%, and format changeovers happened 8–10 times per shift as the operator worked through the list.
After deploying Deckle Plus, the planning team began entering pending finished roll orders per format. The optimizer calculated the combination of 210mm, 100mm, and 230mm rolls that best used the 2800mm parent reel width, often finding combinations the operator had never tried, such as 7×210mm + 2×100mm + 1×230mm = 2400mm, significantly better than running formats in isolation. Changeover frequency reduced from 8–10 to 4–5 per shift as similar-width formats were grouped by the optimizer.
Result
Trim waste fell from 2.4% to 0.6%. Changeover frequency reduced by 45%, adding approximately 1.5 productive hours per shift.
The optimizer handles simultaneous finished roll orders in multiple formats (100mm toilet rolls, 150mm kitchen towels, 210mm facial tissue, and 230mm multi-fold tissue), finding combinations that minimize trim across the parent reel's full deckle width.
Tissue grades with specific GSM requirements are configured with their own optimization constraints. The optimizer never groups orders of incompatible GSM values in the same production run, preventing quality mix-ups on high-sensitivity tissue grades.
Parent reels are logged at intake with production date, GSM, and weight. The system allocates parent reel inventory on FIFO basis and deducts consumption per rewinder run, giving the floor team a clear signal of which reel to load next.
The optimizer groups finished roll orders by compatible width combinations to minimize rewinder changeovers per shift. Fewer changeovers means more productive machine time and less setup scrap at each format transition.
Each production run in Deckle Plus links finished roll output to the parent reel that supplied the material. This batch-level traceability from parent reel to customer order satisfies the documentation requirements of modern trade and export customers.
Specific questions about how Deckle Plus handles this use case.
In Deckle Plus, both formats are entered as pending REEL orders with their respective widths and quantities. The optimizer considers combinations of 100mm and 210mm rolls across the 2800mm parent reel deckle; for example, 5×210mm + 4×100mm = 1450mm, leaving significant remaining deckle width for additional rolls. The optimizer evaluates all valid combinations and returns the one that minimizes trim waste across the combined order set.
Parent reels are configured as inventory in Deckle Plus with their GSM value recorded at intake. Each production run is assigned to a specific paper grade (GSM). When you assign a run to 25 GSM facial tissue grade, only 25 GSM parent reels are allocated from inventory for that run. The system prevents a 40 GSM kitchen towel reel from being assigned to a 25 GSM facial tissue run, eliminating the GSM mix-ups that occur when floor teams pull reels without a system.
Yes. Each machine in Deckle Plus is configured separately. A tissue plant can configure a 2800mm rewinder and a 1200mm slitter as separate machines. Finished roll orders (toilet tissue, facial tissue) are assigned to the rewinder. Any slitting operations on parent reel off-cuts or specialty widths are assigned to the slitter. Both machines appear in the dashboard with separate run histories and inventory consumption.
Yes. Deckle Plus maintains a parent reel-to-finished roll traceability link per production run. Each run record stores which parent reels were consumed (by lot and receipt date), which finished roll orders were produced, waste events logged, and the delivery challan generated on close. This full chain of custody from parent reel intake to finished roll dispatch is accessible at any time and can be provided to export customers as part of quality documentation.
A tissue plant with 4 finished roll formats and 2 rewinders typically goes live in 48 hours with onboarding support from the Deckle Plus team. The configuration involves: setting up 2 machine records (deckle width and blade count per rewinder), adding 4 paper types (one per tissue grade/format), and entering the first batch of customer orders. The onboarding call covers all of this in one session. From the second week, the planning team typically needs 10–15 minutes per shift to optimize and confirm the rewinder plan.
Book a 20-minute call. We'll confirm Deckle Plus fits your specific workflow and show you a live optimization on your order data before you invest any further time.