Featured Stories
-
Elevating Pouch Manufacturing with Pearl Technologies' Cutting-Edge Solutions
For manufacturers seeking efficiency, precision, and safety in pouch production, Pearl delivers unmatched innovation across three standout... -
Faster Product Composition Analysis Equals Better Quality Assurance
Near Instant Testing and Reduced Costs to be Found -
Methods to Precisely Measure Tension and Web Control
How to Control Automatically Within Set Parameters
News | New Products
-
Convertech Brand to Fully Transition to Double E Group Same Team, Same Excellence, Unified Name
Double E Group has announced that Convertech, one of its subsidiaries and a trusted provider of core chucks and shaft solutions for the converting industry, will now operate solely under the Double E Group brand.
-
Pulse is Making Print Simple at Labelexpo Europe 2025
Narrow web ink specialist Pulse is Making Print Simple at Labelexpo Europe 2025, as it challenges flexo printers to rethink how they work and shows solutions that turn production bottlenecks into revenue generators.
-
ROTOCON to debut at Labelexpo Europe with three machine demonstrations
ROTOCON will make its Labelexpo Europe debut, exhibiting together with HS Machinery on stand 4D21.
-
At Interphex Japan, IL Group to Showcase Innovative Labeling Solutions and Contract Packaging Services
IL Group, a specialist in multifunctional labeling solutions for the pharmaceuticals and healthcare sectors
-
Revolutionizing Adherence: Clinical Trials Go Digital with Enhanced Key-Pak®
Keystone Folding Box Co., a leading provider of paperboard packaging solutions, has announced a strategic partnership with Med-Con Technologies
-
Innovating for Circularity: How New Sustainability Initiatives Are Shaping the Future of Labeling
In the face of growing regulatory, environmental and consumer pressures, the packaging and labeling industry continues to advance technologies and solutions that help to support a circular economy.
-
New Product Development: RKW Horizon®–MDO-PE Films with EVOH Barrier
RKW Horizon® is the new generation of sustainable PE plastic films based on the latest MDO technology.
Expert Advice
Web Lines | Why Bigger Cores?
- Published: November 16, 2012, By Timothy J. Walker
Bigger cores avoid many winding defects. I like to joke that the ideal wound roll is a gigantic core with one wrap on it. Think about it.
Bigger cores have fewer layers for a given length of web on the core. Fewer layers of build up mean less magnifying of long-term thickness variations, less significant hardbands, and less winding-induced bagginess. Fewer layers mean less near core pressure buildup and high-pressure defects, such as coining, core impressions, blocking, starring/spoking, and core crushing.
A smaller change from core diameter to final roll diameter means a smaller torque range requirement for a given roll and a winder with a wider tension range able to handle a great variety of products.
The greatest benefit of bigger cores is in torque transmission and associated telescoping. Near core layers have two strikes against them in the challenge of transmitting center winding torque into outer layer winding tension. First, they are at a mechanical disadvantage to the tension at the outside of the roll. Second, they have less area per layer to develop the friction needed to transmit torque. Bigger cores eliminate the near core layers and their low torque transmission capacity.
Diameter will increase, but the diameter increase in moving from a 3-in. (75-mm) to 6-in. (150-mm) inner diameter core is not much. For a 20-in. (0.5-m) diameter roller, moving from a 4-in. outer diameter to a 7-in. outer diameter (assumes a 0.5-in. core wall thickness) only increases the final diameter by 0.85 in.
Yes, I know your customer wants everything on a 3-in. core. Yes, I know that 6-in. cores cost more than 3-in. cores. Yes, I know that 6-in. shafts and core chucks cost more than 3-in. shafts and chucks. This just means the change has to be justified.
Count up your waste from hardbands, core impressions, bagginess, blocking, spoking, and telescoping and see if the move to larger cores is justified. If you are winding rolls that simply move from your coater to your slitter, calculate the costs and savings of winding on reusable metal drum cores.
Web handling expert Tim Walker, president of TJWalker+Assoc., has 25 years of experience in web processes, education, development, and production problem solving. Contact him at 651-686-5400; tjwalker@tjwa.com; www.webhandling.com.