reducing waste material and increasing …...example of a butt splice made on a zero -speed...

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


APPLICATIONS OF AUTOMATIC 0-SPEED SPLICERS:


EVERY KIND OF APPLICATION

• EXTRUSION • PAPER COATING • LAMINATING • PRINTING • PACKAGING: LIQUID, ASSEPTIC, FOOD, OTHERS…

MATERIALS WELL SUITED FOR AUTOMATIC 0-SPEED SPLICERS:


ALL KIND OF MATERIAL

• PAPER-BOARD • PAPER • TISSUE & TOWEL • FILM & FLEXIBLE PACKAGING • NONWOVEN

FIELD PROVEN & TESTED:


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


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



ADVANTAGES

Reduced installation space depending on design

Lower initial investment

Operator familiarity

Industry standard for 50 years



• “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


http://www.linkedin.com/in/joegotshall

reducing waste material and increasing …...example of a butt splice made on a zero -speed...

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