PRIMIR study provides the latest word on ultraviolet and electron beam curing in printing.Read more
Ellis Paperbox added Eagle Systems' cold foil unit to a new Komori press, pleasing customers looking for shine at an affordable price.Read more
Fluid preparation and delivery may be ancillary to the coating process, but they are critical to the coating outcome.Read more
PFFC's "Static Beat" columnist Kelly Robinson is part of expanded "Ask the Experts" program. Kelly and "Coating Matters" columnist Mark Miller present at CEMA …Read more
News | New Products
EcoCortec VpCI films and bags, available in custom sizes and shapes, are said to offer strong protection for metal parts
Program allows companies to personalize FTA books with their logos as gifts to customers, prospects, etc.
A WorldStar 2015 Packaging Award honors company for fold-over blister card aimed to maximize billboard space and minimize material usage
The 2nd edition of Cartons, Crates, and Corrugated Board includes expanded data on tests, designs, materials, and regulations
Line is said to offer high performance and long bath life plus many environmental benefits
Printing solution, which can be integrated inline with converting machines for disposable sanitary napkins, applies patterns on inside of napkin
The NEOS Series, which will be introduced at ICE Europe, is said to be powerful and intelligent and to operate at high speeds
Directories | Reports
PFFC brings you exclusive White Papers from our online sponsors.
Visit Kelly on Static from Static control expert Dr. Kelly Robinson, president of Electrostatic Answers; Kelly has 27+ years of experience in problem-solving and consulting.
Visit Tim's Web Lines to handle and wind your paper, film, foil, and similar products. Take advantage of Tim’s 25+ years just like over 100 converters have.
Visit Mark's Coating Matters from fluid coating expert Mark D. Miller; Process improvement and project management for precision roll-to-roll coating applications.
Visit Marketing Mojo for dynamic marketing insights from Stephanie Millman that inspire new ideas on how to stay on top of your customer’s mind.
Visit Yo’s Yarns to share the thoughts, impressions, experiences, and news that impact the converting industry. . . or anything else that happens to be on her mind!
Visit Tom's Poly Ploys, where Tom will be writing on various topics that the typical polymer processor would encounter on the job.
Most Recent Posts:
- April 01, 2007, By Timothy J. Walker, TJWalker & Assoc. Inc.
This is the first of four columns on baggy webs, starting with understanding the problems they create.
To most converters, the ideal web is one that is uniform in all aspects, especially geometry. It is uniform in thickness, width, and length. If you cut an ideal web, it will form into rolls, slit strands, or sheets that are identical and will delight customers. Ideal webs often are seen in elevation drawings of web lines, represented as perfectly straight lines that travel from one roller tangent point to another. When you see an ideal web running, you may confuse it for a pane of glass. That's the ideal (i.e., dream) world.
The nightmare that spoils the ideal dream for many converters is a baggy web, one with non-uniform geometry in the plane of the web, usually crossweb variations in length.
Web bagginess is one of the main quality complaints about webs bought in roll form. Instead of forming glass-like straight and flat web paths through the machine, baggy webs droop and flutter like sheets on a clothes line. When you see this web running, you'll think about things such as broken wings, rippled chips, and hammocks. The nightmares of baggy webs keep many a converter awake at night.
What problems do baggy webs cause?
Baggy webs look bad, at least when they are under no or low tension. It will not matter that some amount of bagginess is inherent in all webs or that a slight bagginess can be pulled out with tension and cause no measureable performance problems. For some people, looks are everything.
Most baggy webs, due to their crossweb length variations, will have crossweb tension and strain variations, leading to myriad potential problems.
In some precision coating methods, such as kiss gravure or fluid bearing dies, web tension directly affects coating thickness, so a baggy web leads to crossweb coating variations.
Low-tension lanes of a baggy web may see poor slit edge quality or failure to cut. Strands cut from low-tension lanes may go loose after slitting, leading to weave in wound roll or wrapped rollers and web breaks.
Wound roll tightness is highly sensitive to web tension. A baggy web will have crossweb tension variations that will lead to crossweb variations in roll tightness. Crossweb roll variations may be minor in winding a single wide roll but cause high waste in lock-bar winding after slitting (creating sales for differential winding shaft suppliers).
Registration to pre-printed web may be impossible when yielding within the wound roll produces baggy web and out-of-spec pattern dimensions.
Corona treatment errors
Lanes of baggy web that carry no or low tension will air-lubricate on rollers, which leads to unwanted backside treatment.
Webs with asymmetrical bagginess will have a weak but real tendency to shift toward their low tension sides, especially with long spans, low tension, and in air flotation ovens.
The last and biggest problem with baggy webs is that they lead to increased wrinkle waste. Baggy webs with loose lanes or centers will wrinkle in long spans, especially if combined with subtle roller misalignment. Unless sufficiently tensioned to avoid loose lanes, all baggy webs will have trouble running through nips without wrinkles.
I hate to leave you with these nightmares, but you must face your demons before you can exorcise them. Over the next three columns, I will try to make your baggy web nightmares go away by reviewing options to measure the problem, helping you understand root causes, and advising you on how to de-sensitize your process to baggy webs.