Increasing Productivity on R2R Processing Lines with Superior Web Handling

Presented by Duane Smith, Davis-Standard

Increasing Productivity on R2R Processing Lines with Superior Web Handling

Productivity demands for the Flexible Packaging and Converting Industries are to consistently produce and convert thinner and wider web materials at ever-increasing production speeds on roll-to-roll processing lines.  The challenge of conveying these thinner webs at lighter tensions and higher speeds requires special attention to the web handling components to handle a wide variety of web substrates through the process without distortion or defects such as scratches and wrinkles.

Consistent Defect Free Production of Thinner Webs at Higher Outputs requires: Superior Unwind/Splicing for consistent introduction of new rolls of material without tension upsets. These more delicate web materials need to be processed at lighter tensions.  The ability to control these light tensions requires optimized tension sensing and control systems.   Web handling support rollers need to be properly designed for proper web tracking and to ensure that these do not produce additional web tension.  Thin webs are significantly more prone to wrinkling. Therefore, the spacing and alignment of the web conveyance rollers is much more critical.  Positive traction between the web and web support rollers is very important to ensure that the web does not weave through the process and the web is not scratched by a speed mismatch between the web and slower turning support rollers.  Web spreading is an important component for proper web handling.  Positive traction between the web and the spreader is critical to achieve positive spreading action of the web.  Also, positive web traction is critical to ensure proper web guiding off the unwinding operation and through critical web position processes. This Webinar gives suggestions to optimize each of these web handling components.

Then the secret of consistently winding quality rolls is revealed.  This includes the importance of getting a good hard wrinkle free starts and when winding rolls of material with the proper inwound tension.   The roll hardness principles are discussed and Rules of Thumb for starting values for various web materials.  Then the various types of winding web transfer system are presented and the pro and cons of each of these transfer systems.