Latest developments – slitting & rewinding
Due to potential inefficiencies of the slitting & rewinding process there are considerable savings which can be made. A simple example would be the current necessity to stop the slitting process for every ‘flag’ (print, lamination or splice defect) in the parent roll. With today’s 100% inspection systems it is possible to electronically map the roll directly from the printing process, review the defects and allow the inspection system to take control of the slitter. This enables automatic, fast and accurate stopping of the slitter for cross web faults or to allow lane faults through the slitter to be edited off-line after slitting – which increases the slitter efficiency multi-fold.
Tension control is one of the most important functions of the slitter rewinder and critical to converters’ customers. Often, many problems will not be detected until the end user is packaging a product on high speed packaging lines. Here, tension variation throughout the reel of packaging material can cause significant production issues on packaging machinery. Control and adjustment of tension in the slitting & rewinding process has evolved dramatically and today’s modern automated systems eliminate the ‘guess work’ of adjustment. This ensures uniform web control with feedback to the differential rewind shafts.
Slitting accuracy and web guidance are also vital functions of the slitting & rewinding process. If the guiding system is not maintaining control of the web position through the knives then a complete job can be wasted. If the knife positions are not set accurately then the same result will happen.
When considering investment in new slitting & rewinding technology, converters need to take into consideration their own production requirements and configure the machine to meet the following demands:
- What size (diameter) parent rolls are required? How many flags (faults) on average does each roll contain?
- What are the characteristics of the material to be processed? Are materials extendable? What is the min. & max. thickness of materials? Are there any adhesive or cold seal applications?
- Slit width requirements – what are the min. & max. slit widths required for processing?
- Do additional processes need to be included in the slitting operation? Eg. Laser scoring, laser perforation or web treatment?
- Logistics – how will parent rolls be transported from WIP to the slitter? Are product samples required from each reel? What label sizes are required and where should they be appled? How will the slit reels be unloaded and palletized?
Titan first considered sustainability with the introduction of the first generation Titan ER610 compact duplex slitter back in 2007 - indeed the ER stands for Ecological Rewinder! This machine incorporates design features to reduce energy consumption and shipping/logistics requirements and also to reduce operator intervention – all of which reduces the ‘carbon footprint’ of the machine.
These features have now been incorporated into all Titan models since the ER610 was introduced and can now be seen in the latest generation machine - the Titan SR800 Duplex slitter rewinder which is just being introduced to the market. The SR800 is a direct replacement of the highly successful SR8 Series slitter, but offers even greater productivity, reduced energy consumption and even better ergonomics for the operator.
The Titan SR800 Duplex slitter is available in 1350mm & 1650mm (53 & 65in) web widths and further strengthens the Titan portfolio of high performance slitting & rewinding solutions. Its modular design provides an economic and simple solution for upgrading to higher levels of automation as production demands increase. Automation options can include automatic knife & laser core positioning systems and fully automatic slit reel unloading.
The SR800 features the latest mechanical, hydraulic, pneumatic, electronic and computer control technology to assure converters of consistent, high quality rewind reels with improved levels of sustainability, productivity and easy job repeatability.
The SR800 can process a wide range of flexible materials including plain, coated, printed or metallized plastic films, laminates and label materials from 20 to 200 micron and paper from 40 to 200 gsm. It has a maximum production speed of 700m/min. (2,300ft/min) with rewind diameters up to 800mm (32in) and slit widths as narrow as 20mm (0.8in).