The Converting Relay Race: Part 1

Converting productivity is a race to see how much material we can get through our process. Instead of a marathon, with one runner going the distance, converting processes are more like relay races, with a series of runners. Like a relay, we need to pass baton from roll to roll so each roll can run their leg of the race.

Concave Rollers Pros & Cons

Got some nasty wrinkles on a roller? Some tape here, some tape there—wrinkles be gone. Adding tape collars or bands to a cylindrical roller just under each of the web’s edges turns a cylindrical roller into a wrinkle-stopping concave roller.

You're Too Tense!

When planning to purchase tension controls, there is a lot for the converter to consider. "It's not just as easy as buying brand X controller and throwing it on your system and away you go." Here are some of the important questions to consider.

Drawing Conclusions: Part II

The principles of draw control usually create a good deal of confusion. Let’s pick up where we left off in my last column and see if we can move from drawing confusions to draw control conclusions.

Introduction to Roll Handling

Proper roll handling methods are required to ensure plant personnel safety and to minimize losses associated with roll damage.

Drawing Conclusions: Part 1

In planning the tension control for any web line, there are only three options: tension control, torque control, and draw control. Between any two rollers or rolls controlled by a motor, brake, or clutch, you have to select one of these three choices.

Clean Thinking

What is your definition of clean? What people think of as "clean enough" in their home is staggeringly different. Hopefully, your definition for your converting operation is the same as that of your customers.

Detecting the Edge

Web guides have evolved dramatically since their first appearance on converting lines in the 1930s. Electronic edge detectors and electric motors gradually displaced pneumatics and hydraulics as demand grew for greater accuracy and reliability, and tolerance for leaky hydraulics diminished. The earliest electronic systems were far from perfect—in particular the edge detectors were sensitive to dust and temperature swings—but they were a big improvement over their predecessors

Get Out of the Scroll Business

Curl will kill your product. How do webs end up curly? Let’s go over the top causes and consider how to eliminate them.

Why Tension?

Why is tensioning such a crucial first step? What are the benefits of a well-tensioned web? What is the right amount of tension for your product? Don’t slack off now...keep reading for these answers and more.

Who Likes Film?

Customers like films because they are cool. Films can be clear, thin, shiny, clean, and elastic. Product designers like films because they are functional. Films can improve a product’s break strength, tear resistance, and gas barrier performance. Process people like films because…wait. Do process people like films?

Web Tension 101

Typically, tension is measured in PLI (pounds per linear inch) in the US. If you know PLI and you want to know total tension applied to the web, multiply PLI times the width of the material in inches. If you know total pounds of tension applied to the web and you want to know PLI, divide the total pounds of tension across the web by the width of the web in inches.

The Harms of Harmony

From a simple handling viewpoint, these harmonic motion hiccups may be no problem, but combined with coating, extrusion, slitting, or winding operations, they may lead to waste.

Mechanics of Tension Control, Part II

For this basic tutorial in the mechanics of web tension control, tension is defined as the force applied to a continuous web of material in the machine direction.

Slitting Debris: Cracking the Case

Dust and debris are a common but unwanted side product of slitting. Slitting debris comprises the small particles that break off a product's edge during the slitting process. It is created through fracture and abrasion. Uncontrolled slitting debris will lead to defects in your customer's product and equipment downtime.

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