From Japan to Italy: How Wet Embossing Came About

When our Sales Director, Carlo Berti, went to Japan in 2017, he immediately noticed the development potential and revolutionary impact of the prototype by Kenji Taniguchi, R&D Manager at Kawano Paper. 

Upon his return to Italy, he told our Chairman, Giovanni Gambini, about this innovative embosser. Gambini replied: “We have found the product to develop. We have the future of tissue in our hands.” 

Today, Taniguchi is visiting our R&D plant in Italy to personally follow the progress of his creation and contribute to the advancement of this innovative technology. 

The last time he visited the TissueHub, we interviewed him. 

How Was the Idea of AirMill Born, Combining Water and Heat in the Converting Process? 

“It started as a game. If you press a coin hard against a paper handkerchief, the decoration engraved on the coin remains imprinted. The imprint is slight but still visible. I thought: maybe by adding a little water, the impression would become even clearer. I tried it and was amazed—wetting the paper and pressing the coin produced a much more pronounced result.” 

This experiment happened about ten years before the birth of AirMill itself. However, the idea had already taken root. 

How Did You Turn This Idea Into a Real Project? 

“I also tried the technique on normal paper, like photocopy paper, but even when wet, no mark remained. A lighter paper was needed to achieve a visible imprint. It worked better on layered creped paper; just a little water made the coin’s decoration emerge. To me, it looked like magic, and I thought: this could be the starting point for something new.” 

Taniguchi started thinking about how to apply this effect. Working in a paper mill, it occurred to him to introduce water before embossing—the part of the process that engraves designs into paper—just as a coin impresses a handkerchief. The result was a significantly more beautiful and defined decoration. 

How Was the System Initially Used? 

“At the time, it was just a prototype used as a nearly handcrafted method. We had a spray system, an early version of what the Weko system does today, but no real combination of water sprays and heat. The hot rolls we now know did not exist. Water was sprayed before embossing, leaving the paper wet, which then needed drying. That’s when I had the idea to invent heated rolls, combining both processes. The results were exceptional.” 

The decoration was not only more aesthetically pleasing but also improved the final product’s thickness and absorbency, enhancing its characteristics and encouraging further development of the idea. 

What Was Gambini’s Role in AirMill’s Development? 

Gambini’s technology enabled the industrial development of what had been just an idea and a prototype. Taniguchi’s first version was small and slow, operating at just 200 m/min. 

It was Giovanni Gambini who decided to transform it into a functional machine for a converting line capable of reaching 700 m/min. 

What Potential Did Gambini See in AirMill? 

The AirMill system can create textured paper comparable to TAD (Through Air Drying)—a technology widespread in the U.S. but typically expensive and reliant on complex papermaking machinery. Gambini realized that AirMill could achieve comparable results within the converting process, significantly reducing costs while maintaining excellent quality. 

Starting from a Japanese prototype, Gambini developed a technology capable of nearly matching TAD results within two years. 

How Is Your Relationship With Gambini? 

“It’s excellent! I work very well with everyone, especially the TissueHub staff and salespeople. We run numerous tests and verify them in the lab to identify improvements. TissueHub fosters an exceptionally creative atmosphere, making it natural to innovate and strive for better products.” 

What Is Your Background? 

“I graduated in Chemistry, specializing in Polymer Chemistry, and have been working at Kawano Paper for over thirty years. My first invention was a facial tissue paper retaining a small percentage of humidity, giving it a silk-like effect. In Japan, this product, comprising glycerin, sorbitol, and oil, represents 10% of the facial tissue market despite being three times the cost of standard paper.” 

What Are Your Hobbies? 

“I love freehand drawing, especially landscapes and portraits. Observing and capturing on canvas helps me focus on my surroundings. I also bike to and from work daily, a 25-minute ride each way. With two sons, a daughter, and four grandchildren, I don’t have much time for hobbies, but this is my way of caring for the environment—besides inventing AirMill!” 

ABOUT AIRMILL 

AirMill: Endless Innovation 

AirMill is an evolving technology, delivering continuous benefits and applications: 

• Increased volume 

• Enhanced strength 

• Textured appearance 

• Point-to-point effects 

The latest advancement, C-TAD Punta-Calda, offers improved features at lower costs compared to traditional systems. 

Discover more about AirMill here. 

This article was written by the Gambini team. You can learn more about the company and its solutions by visiting their website.