reducing waste material and increasing …...example of a butt splice made on a zero -speed...
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Reducing Waste Material and Increasing Productivity Through Butt Splicing
Joe Gotshall – [email protected] 510-290-4995
http://www.linkedin.com/in/joegotshall
Zero Speed Splicing Technology
Example of a Butt Splice made on a Zero-Speed Continuous Splicing Unit
0-speed unwind splicers
Joe Gotshall – [email protected] 510-290-4995
APPLICATIONS OF AUTOMATIC 0-SPEED SPLICERS:
0-speed unwind splicers
EVERY KIND OF APPLICATION
• EXTRUSION • PAPER COATING • LAMINATING • PRINTING • PACKAGING: LIQUID, ASSEPTIC, FOOD, OTHERS…
MATERIALS WELL SUITED FOR AUTOMATIC 0-SPEED SPLICERS:
0-speed unwind splicers
ALL KIND OF MATERIAL
• PAPER-BOARD • PAPER • TISSUE & TOWEL • FILM & FLEXIBLE PACKAGING • NONWOVEN
FIELD PROVEN & TESTED:
0-speed unwind splicers
GRAMAGE RANGE:
• From 15 gr/m2 up to 500 gr/m2
WEB TENSION RANGE: • From 15 N/m up to 1100 N/m ROLL DIMENSIONS RANGE: • Up to 3,5 m diameter. • Up to 4,5 m Web width • Up to 9,5 Tm weight.
9 – 310 lbs / 3000 ft^2
0.06 – 7 PLI
11.5 feet diameter 15 feet web width 21,000 lbs
CORE REASONS FOR TECHNICAL SUPERIORITY
• 1.- “ZERO SPEED” SPLICING VS “FLYING SPLICE”
• 2.- BUTT SPLICE VS OVERLAP SPLICE WITH TAIL
• 3.- CONSTANT WEB TENSION CONTROL and WASTE REDUCTION
0-speed unwind splicers
In the Flying Splice, two rolls are accelerated to nearly the same speed and then…
TYPE: “FLYING SPLICE”
Zerospeed vs Flyingsplice
DISADVANTAGES
Lower Reliability
Splice with adhesive and tail inconsistency
Complex Splice Preparation takes longer and requires precision
Reliability reduces at higher speeds
Unsteady Web Tension control during the Splice
Odd or Potato shaped rolls reduce reliability further
It’s not possible to finish the Parent Roll – waste material
TYPE: “FLYING SPLICE”
Zerospeed vs Flyingsplice
ADVANTAGES
Reduced installation space depending on design
Lower initial investment
Operator familiarity
Industry standard for 50 years
TYPE: “FLYING SPLICE”
Zerospeed vs Flyingsplice
• “ZERO SPEED” SPLICE = NON STOP SPLICE. HOW IT WORKS:
TYPE: “ZERO SPEED” SPLICE
Zerospeed vs flyingsplice
• ADVANTAGES
• Almost 100% splice reliability even if the new roll is out of round
• Increased Productivity
• Programmable, automatic, simple, easy and rapid Splice preparation
• Bigger range of speeds and paper grades
• Maximum performance and reliability at higher speeds
• Less paper waste. Less paper is left on the core:
• Smaller adhesive tape consumption
• Profitability increased
• Ability to RUN-OFF the core. Leave NO PAPER on the core after each Splice
TYPE: “ZERO SPEED” SPLICE
Zerospeed vs flyingsplice
buttsplice
100 mm
0 ÷ 1 mm.
NEW PAPER OLD PAPER
TAPE
OLD PAPER
50 mm TAPE
NEW PAPER
0-Speed Splicing equipment can make either BUTT SPLICE OR OVERLAP WITHOUT TAIL
• Butt Splice
• Overlap NO TAIL
4 inches tape width
• TAIL FREE SPLICE
• No tail to interrupt the extrusion melt curtain
• No tail to damage the die lips or die gap setting
• No tail to damage treater electrodes
• No tail to interfere with printing decks or primer coaters
buttsplice
webtensioncontrol
CONSTANT WEB TENSION CONTROL, through load cell and/or dancer roller
rapidpaybacktime
HIGH SPLICE RELIABILITY (no miss splices)
BUTT SPLICES (continuous production)
ACCURATE WEB TENSION CONTROL (product quality)
RUN OFF THE CORE (higher efficiency - when available)
PRODUCTION INCREASE – INCREASED PRODUCTIVITY
REDUCED PAPER WASTE – INCREASED PROFITABILITY
unwindstypes
Floor Pick-Up
unwindstypes
Turret Type
0-Speed splicing users
Reducing Waste Material and Increasing Productivity Through Butt Splicing
Joe Gotshall – [email protected] 510-290-4995
http://www.linkedin.com/in/joegotshall