
	Core Support System

How to Get the Most From Your Leaf-Type Air Shafts

Air shafts are core support mechanisms that slide inside of a core of a roll or material. They serve as a coupling mechanism between your material roll core and a power transmission device like a brake on an unwind or a drive on a rewind.

Leaf type air shafts, like CAC's COR-LOK series air shafts, utilize an expanding element under leaves mounted around the circumference of the air shaft which move outward to engage a roll core. When air pressure is applied to the leaf type air shaft the expanding element expands under the air shaft leaves which actuates the leaves.

Things to consider when utilizing leaf type air shaft technology:

Many leaf type air shafts are designed to be light weight. Take advantage of this feature to improve your ergonomics.
Leaf type air shafts deliver lots of torque to your core so they are well suited for low to high tension applications.
Zero core damage will occur with the use of this type of air shaft. So, if you re-use your cores, these air shafts are the perfect choice.
Inflate this type of air shaft according to the manufacturers recommended air pressure to take advantage of their high torque capability. If the core slips on the leaves (due to improper inflation) leaf damage, due to unnecessary wear will occur.
Leaf type air shafts, typically, do not have as much beam strength as their button type or lug type air shaft counterparts. Keep this in mind when supporting heavy rolls of material.

Leaf type air shafts are an excellent choice for holding unwind and rewind rolls. When properly applied they will provide years of light weight, reliable service.

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Jeff Damour

Core Holding Options

Jeffrey Damour

Engineering Manager at Converter Accessory Corporation

September 30, 2024

If you unwind and rewind rolls of material, you most likely must decide on the best type of core holding for your converting operation. That is, how you hold the core of your material roll for unwinding or rewinding. There is a multitude of core holders from which to choose. Here are the most common types:

Air shaft – a deflated air shaft is inserted into a core. It is then inflated with compressed air to activate a core gripping mechanism.

Main Advantages:

· Easiest to use

· Works well for high tension (torque requirement) applications

· Good for heavy rolls

Main disadvantages:

· Most expensive

· Custom manufactured with longer lead-times

· Can be heavy for handling

Dual air chuck – dual air chucks are similar to air shafts but utilize two, short, independently inflated air chucks mounted on a thru shaft.

Main advantages:

· May be lighter weight than an air shaft

· Cost effective, usually stocked

· Easy to use

Main disadvantages:

· Must move air chucks for varying web widths

· Must be inflated independently (two places, instead of one)

· Less torque for lighter tension applications

Tandem air chuck – Tandem air chucks are similar to dual chucks but they can be inflated in one position because they use pneumatic tubing between chucks.

Main advantages:

· Air chuck advantages (above) but faster roll loading and unloading with one inflation point

· Less expensive than air shafts

· May be faster delivery than a custom air shaft

Main disadvantages:

· Must be moved in and out for varying web widths

· Less torque than air shafts

· More expensive than dual air chucks

Dual mechanical chucks – mechanical chucks lock cores in place without the use of air. They are very similar to their air chuck counterparts, but no air required.

Main advantages:

· No air required, may be useful for specific applications

· Some designs are “torque sensitive” meaning they work GREAT for HIGH torque applications where tension may be very high

· Cost effective

Main disadvantages:

· May be harder to load and unload than air chucks

· Core dust may affect operation

· Minor diameter to expanded diameter range does not allow for a lot of core size variance.

Chuck (air or mechanical) and end plug – This type of core holding arrangement can use air or mechanical chucks and a “dummy” end plug. The end plug is a cone shaped device that simply supports one end of the core while the chuck supports the opposite core end. The chuck delivers the torque to lock the core in place.

Main advantages:

· Cost effective

· Simple

· End plug includes a core stop flange for core alignment in the unwind or rewind

Main disadvantage:

· Half the torque output, compared to dual chucks

· Not well suited for wide widths, large diameter rolls and / or high web tension

Core cones – the simplest of all core holding methods. This system uses two cone shaped, serrated cones that are pressed into each core end to hold and lock the core in place.

Main advantages:

· Extremely cost effective

· Great for crushed cores

· Very simple to use

Main disadvantages:

· Least operator friendly

· Limited to certain core sizes

· Cone must be removed to load and unload

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Jeff Damour

Nonwovens Producer Turns to Single Source for Two Effective Upgrades

Trenton, South Carolina: Bondex, a Trenton, South Carolina manufacturer of nonwovens, solved two nagging production problems with mechanical solutions from a single source, Converter Accessory Corporation (CAC).

The first problem was with an air shaft, button type design that clogged and became ineffective under production conditions.

According to Charlie Waters, Bondex Production Manager, Bondex's nonwovens production was plagued by frequent disruption when material; fibers and dust, from roll cores built up in and then clogged the button type air bladder openings. Not only did this accelerate wear on the bladders, but also, as the openings became clogged, prevented firm, uniform contact between the buttons and the cores. Operation of the air shaft became ineffective, production had to be shut down and the air shafts serviced. Frequently, the bladders in the button type air shafts were too difficult to replace in house and had to be sent to the manufacturer for refitting.

For Waters, the amount of downtime caused by air shaft failures was unacceptable. When salesman John Burch from Louis P. Batson Company, a Converter Accessory Corporation (CAC) agent, presented COR-LOK air shafts as an alternative, Waters was intrigued enough to give one a trial.

Unlike button-type systems, COR-LOK air shafts and chucks feature a tubing design contoured to match the geometry of its unique, spiraled shaft body. These inflatable tubes are able to match and usually exceed the gripping power of other systems, including button-type. Importantly, so far as Waters was concerned, CAC's COR-LOK air shafts offer exceptionally easy maintenance and tube replacement.

CAC's tubing fits all CAC air shafts and chucks. It can be ordered and stocked in advance and cut to length, on site, to match any COR-LOK air shaft. This feature is especially important in a facility using a diversity of air shaft and chuck sizes. The tubing itself is mechanically fixed to the air valve rather than vulcanized, and thus can be easily replaced by virtually any operator using simple hand tools. The tubing requires only 60 to 120 psi to fully inflate.

After the first COR-LOK air shaft was installed and tested on Bondex's nonwovens production line, the results were so impressive that Waters decided to replace the remaining button-type systems with the CAC technology.

The second production problem, less urgent but none-the-less a stewing annoyance in the background, was with a venturi trim removal system that sometimes clogged, was limited in how far it blew waste, and too limited in the volume of trim it could handle.

Burch said he had a solution to the trim removal annoyance as well and introduced Bondex's Waters to CAC's Fox TrimAway ®venturi and blower based trim removal system. CAC offers 30 standard systems with blowers from 1 HP to 15 HP. All components are engineered to match each customer's specifications. Components include a unique, adjustable venturi, regenerative blower, pickup nozzle, Y connectors, collection centers, flexible ducts, motor starters, trim choppers, filters and silencers(if needed); it is a complete, ready-to-work trim removal system fully supported by readily available spare parts. ”Since we liked the air shaft and were impressed with the sensible engineering behind it, we were pleased to find the same common sense approach in the Fox TrimAway.“ Waters said. Waters says the FOX TrimAway runs quieter, handles more trim and heavier trim, sends it farther and is more reliable than the system Bondex had before. ”I don't think it ever clogs,“ Waters said. Finally, Waters said, ”We really appreciate the efficient, cost effective design engineering behind both these systems. They install easily. They run like they're supposed to and you can service them yourself, in house, with your own people. Can't beat that.“ Written By: Jeffrey Damour, Sales Manager, Converter Accessory Corporation, Wind Gap, PA, Phone - 800-433-2413

New On Shaft Inflation Toggle Valve Air Shaft Makes Roll Changes More Efficient

Converter Accessory Corporation (CAC®) is introducing a patented new inflation toggle valve COR-LOK® air shaft option, toggle valve COR-LOK air shaft, that helps reduce roll changeover times. Toggle valve COR-LOK air shaft employs standard rotary union for pneumatic hook-up and is specifically engineered for use in cantilevered applications. It is available in COR-LOK air shafts in 2 to 18 inch diameters.

According to Jeff Damour, CAC engineering manager, the main advantage of the toggle valve COR-LOK air shaft is that it facilitates rapid roll changeovers. Since the easily reached toggle valve is built into the end of the air shaft, an operator does not have to leave the station to access a remote inflation control or retrieve any tools.

”The toggle valve COR-LOK air shaft is a simple design that makes an exceptional contribution to efficiency," Damour said. "This option is well designed for use with label presses and is available in stainless steel for washdowns in food grade applications and offers all the advantages of our other COR-LOK air shafts.“

The toggle valve COR-LOK air shaft system is also compatible with CAC's sleeve-based core adapting option that allows converters to run varying core sizes, both 3“ and 6“ for example, on the same shaft or air shaft. This option allows rapid changeovers between rolls with differing core diameters ranging from 3 to 18 inches. CAC's sleeve-based core adapting system is especially effective in label production and other narrow web operations. It offers converters the additional economical option of employing two short sleeves at each end of the shaft rather than a single, longer sleeve to adapt varying core sizes.

The most recent COR-LOK air shafts and chucks feature a freshly engineered tubing (bladder) design contoured to match the geometry of the company's unique, spiraled shaft body. Compared to previous designs, the economical new contoured tubing allows increased gripping power, a longer tubing life and exceptionally easy replacement. The new COR-LOK air shaft and chuck systems also offer several air valve options intended to match virtually any plant requirements. To fully inflate, they require only 90 to 120 PSI.

COR-LOK tubing is unique in that it can be quickly and easily sized, on site, to match any CAC air shaft or chuck. Tubing lengths can be ordered in advance and stocked, thus minimizing down time, even in plants where a large diversity of air shafts and chuck sizes exists. To facilitate easy changeovers, the tubing is mechanically fixed, rather than vulcanized, to the air valve.

All COR-LOK air shafts and chucks offer exceptional gripping power over the full core length; feature a unique, wear resistant aluminum leaf locking system, and ensure core protection and damage free operation. They are lightweight and carefully designed for easy, safe operation.

CAC hosts an online air shaft support center featured on www.handleyourweb.com offering detailed instruction for servicing air shafts from CAC and other manufacturers. The air shaft support center allows for online ordering of spare parts, including aluminum core cones, tubing, valves and valve cores.

In addition to detailed instruction, online chat is also available, but not required to access information. Currently celebrating its 40th year of success, Converter Accessory Corporation designs, engineers and manufactures web handling equipment for converters of paper, film, foil, nonwovens and textiles. Engineered solutions include high quality, cost effective equipment from the simplest aluminum core cone to the most sophisticated unwind/rewind system. CAC® is represented by knowledgeable sales engineers and provides extensive consultation and post sales support. For more information contact Pam Damour, Converter Accessory Corporation, 201 Alpha Road, Wind Gap, PA 18091-1279, (800) 433-2413, fax (610) 863-7818. cac@epix.net

New Lateral Adjust Option Allows Air Shaft Adjustment on the Fly

Converter Accessory Corporation (CAC®) is introducing a lateral adjust option with its COR-LOK® air shafts for cantilevered installations in narrow web applications.

The lateral adjust option is built into the air shaft and an easily and safely operated handwheel facilitates side to side +/- 4 inch adjustments while the machine is running and production continues. The system includes CAC's exclusive adjustable core stop flange. The air shaft can be inflated through a rotary union via CAC's patented remote toggle valve, or with an air gun.

COR-LOK air shafts with the lateral adjust option feature all the standard engineering features of the standard COR-LOK systems, including a tubing (bladder) design contoured to match the geometry of the company's unique, spiraled shaft body. All COR-LOK air shafts and chucks offer exceptional gripping power over the full core length; feature a unique, wear resistant aluminum leaf locking system, and ensure core protection and damage free operation. They are lightweight and carefully designed for easy, safe operation.

Additionally, lateral adjust COR-LOK systems are easily cleaned and are designed for use in food-grade operations.

Lateral adjust COR-LOK air shafts are available in 2 to 12 inch standard diameters and are capable of handling 500 lbs at speeds to 2000 feet per minute.

According to CAC General Manager Pamela A. DiFrancesca, lateral adjust COR-LOK air shafts address growing market demands for systems that facilitate continuous production and reduce down time.

”Every component of all COR-LOK shafts and chucks, right down to the standardization of air tubing, is aimed at minimizing down time. The lateral adjust system allows narrow web converters to make changes on the fly,“ Damour said ”and offers a production advantage that could prove significant in highly competitive markets.“

Founded in 1974, Converter Accessory Corporation designs, engineers and manufactures web handling equipment for converters of paper, film, foil, nonwovens and textiles. Engineered solutions include high quality, cost effective equipment from the simplest aluminum core cone to the most sophisticated unwind/rewind system. CAC is represented by knowledgeable sales engineers and provides extensive consultation and post sales support.

For more information contact Pam DiFrancesca, Converter Accessory Corporation, 201 Alpha Road, Wind Gap, PA 18091-1279, (800) 433-2413, fax (610) 863-7818. sales@converteraccessory.com Web site: www.converteraccessory.com

New Core Adapters Offers Cost Effective, Simple Answer

CAC (Converter Accessory Corporation) is offering new core adapters with the company's proven COR-LOK® core support technologies. The system uses sleeve based technology featuring CAC's unique split bushing locking design. COR-LOK® core adapters operate to handle core sizes from 2 up to 18 inches in diameter (3 and 6 inch being the most popular).

According to Jeff Damour, CAC's engineering manager, COR-LOK® core adapters are effective with virtually all types of air shafts and thru shafts. CAC's unique split bushing design clamps and releases quickly and easily. It holds the core adapter securely in place and will not mark or damage the air shaft or thru shaft support.

"CAC's new COR-LOK® core adapters offer our customers a cost effective, simple answer to a potentially difficult problem. When the need arises to run larger core diameters than a particular unwind or rewind setup can handle, CAC COR-LOK® core adapters can be used to effectively handle those larger cores." Damour said.

These new core adapters are covered in CAC's new COR-LOK® Core Adapters brochure and on CAC's website on the Core Adapters page. Contact us at 800-433-2413 to receive the brochure.

COR-LOK® pneumatic shafts, chucks and core adapters feature a tubing (bladderless) design, contoured to match the geometry of the company's unique, spiraled shaft body. The contoured tubing allows exceptional, even gripping torque across the full length of the core, a extremely long tubing life and easy replacement. COR-LOK® systems also offer several air valve options intended to match any application requirement. To inflate, they only require 70 PSI and can easily handle up to 120 PSI. COR-LOK® air shafts, chucks and core adapters feature unique, wear resistant aluminum leaf locking system and ensure zero core damage. All models are lightweight and designed for easy, safe operation.

New Cost-Effective Air Chuck is Designed for Demanding Applications

CAC® (Converter Accessory Corporation) adds a new, uniquely designed air chuck to its proven line of COR-LOK® air and mechanical chucks. This new COR-LOK-XE® model air chuck utilizes a pneumatically expanding, spirally wrapped external element to engage the core. These chucks are available for 2" - 18" diameter cores and use split bushings to lock to thru shafts for fast and easy placement and installation.

According to Jeff Damour, CAC's engineering manager, COR-LOK-XE® pneumatic chucks are effective with virtually all types of cores in light to heavy duty applications. CAC's unique split bushing design clamps and releases quickly and easily, holding the COR-LOK-XE® model chuck securely in place and will not mark or damage the thru shaft to which it is mounted.

CAC's® new COR-LOK-XE® model air chucks offer our customers a cost effective, simple answer to demanding applications where effective core holding is required. They are designed with standard, universal parts, so no matter what diameter air chucks our customers use; all parts remain consistent for all sizes. These chucks are designed to last with extremely limited maintenance. However, when maintenance is required, it is done with standard, stocked parts in less than 15 minutes.® Damour said.

COR-LOK-XE® pneumatic chucks feature a tubing (bladderless) design, contoured to match the geometry of the company's unique, spiraled shaft body. The contoured tubing allows exceptional, even gripping torque across the full length of the chuck, an extremely long tubing life and easy replacement. To inflate, they only require 70 PSI and can easily handle up to 120 PSI. COR-LOK-XE® air chucks feature unique, wear resistant external element locking system and ensure zero core damage. All models are lightweight and designed for easy, safe operation.

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	Shaft Support Systems

New Features for ShaftLok® Safety Chucks

Converter Accessory Corporation is introducing new optional features available with its’ popular ShaftLok® safety chuck system.

ShaftLok® safety chucks are now available with a newly designed, spring loaded, hand operated sliding mechanism which ensures the shaft capture plate cannot open without the machine operator physically operating the slider first. Another optional feature is a mounted proximity sensor that will detect whether the capture plate is open or closed.

"Our customers requested these two additional features, so we decided to design them and offer them as optional features within our standard safety chuck system," Jeff Damour, Engineering Manager said.

ShaftLok® safety chucks are an exceptionally rugged method of holding the journals of unwind and rewind shafts. They include shaft capture plates that open only in the up position. They feature replaceable shaft cradle inserts available in square, triangle, diamond and round shaft configurations. Models are available in standard duty, medium duty and heavy duty.

Axially sliding shaft capture plates ensure pinch point free operation.

New Bulldog Tough, Safely Operated Shaft Locking System for Unwind and Rewind Stations

Converter Accessory Corporation (CAC), is introducing a new ”Bulldog” medium weight, low profile Shaft-Lok®, a safely operated shaft holder system for unwind and rewind rolls. Unlike conventional safety chucks, Shaft-Lok® has no pinch points.

According to Jeffrey Damour, CAC Engineering Manager, the pinch point free design offers a level of worker safety unequalled by any other shaft locking systems.

The new mid weight Bulldog Shaft-Lok® series is designed for loads to 3000 pounds and 1 1/2 inch shafts. It joins the light weight system for loads to 1000 pounds, 1 1/4 inch shafts and the heavy duty series for loads to 10,000 pounds and 2 inch shafts.

In all sizes, the CAC Shaft-Lok® opens only in the up position and allows a safe, easy unload operation. All models automatically lock to hold rotating shafts and feature all steel, extra heavy-duty construction, including heavy-duty ball bearings.

All Shaft-Loks® feature replaceable cradles and inserts which are available for square, diamond, triangle, 1/2 round and custom shaped shafts and shaft ends. The system is available in foot or flange mount designs. Skew and lateral adjustment assemblies are also available.

”The new Bulldog system gives customers so many off the shelf options that in practice the benefits match custom designs. The exceptionally safe and reliable Shaft-Lok® system is available for virtually any unwind or rewind system. We can also combine a standard Shaft-Lok® with CAC brakes for a total unwind solution, or offer custom designs to match any brake, clutch or drive a customer selects,“ Damour said.

CAC offers rapid deliveries for Shaft-Lok® units at competitive prices.

New Rugged Design Upgrades Pinch Point Free Shaft Locking System

Wind Gap, Pennsylvania: Converter Accessory Corporation (CAC), Wind Gap, Pennsylvania, is introducing an upgraded, more rugged, more durable. ShaftLock™ safe operation shaft holder for unwind and rewind rolls. The improved system does not compromise any of the features that made the first generation ShaftLock™ systems so successful.

Unlike conventional safety chucks, ShaftLock™ is a safety chuck with no pinch points. According to Jeffrey Damour, CAC Engineering Manager, the pinch point free design offers a level of worker safety unequalled by any other shaft locking systems.

ShaftLock™ opens only in the up position and allows a safe, easy unload operation. ShaftLock™ is available in several models able to handle loads and roll weights up to 5,000 lbs and operate flawlessly at low to high speeds. All models automatically lock to hold rotating shafts and feature all steel, extra heavy-duty construction, including heavy-duty ball bearings.

ShaftLock™ features replaceable cradles and inserts which are available for square, diamond, triangle, 1/2 round and custom shaped shafts and shaft ends. The system is available in foot or flange mount designs. Skew and lateral adjustment assemblies are also available.

”ShaftLock has been very successful in the market. After a close look at performance we decided customers could benefit from a heavier duty model. Our ability to custom engineer most of our products, including ShaftLock, allows us to quickly respond to customers’ requests. ShaftLock is an exceptionally safe and reliable system for virtually any unwind or rewind system. We can combine a standard ShaftLock with CAC brakes for a total unwind solution, or offer custom designs to match any brake, clutch or drive a customer selects,“ Damour said.

CAC offers rapid deliveries for standard units. According to Damour, Shaft Lock® systems are competitively priced.

New Pinch Point Free Shaft Locking System

Introducing Shaft-Lok® a new safely operated shaft holder system for unwind and rewind rolls. Unlike conventional safety chucks, Shaft-Lok® has no pinch points.

According to Jeff Damour, CAC Engineering Manager, the pinch point free design offers a level of worker safety unequalled by any other shaft locking system.

Shaft-Lok® opens only in the up position and allows a safe, easy unload operation. Shaft-Lok® is available in several models able to handle loads and weights up to 5,000 lbs. and operate flawlessly at low to high speeds. All models automatically lock to hold rotating shafts and feature all steel, extra heavy-duty construction, including heavy duty ball bearings.

Shaft-Lok® features replaceable cradles and inserts which are available for square, diamond, triangle, 1/2 round and custom shaped shafts and shaft ends. The system is available in foot or flange mount designs. Skew and lateral adjustment assemblies are also available.

"Our ability to custom engineer most of our products, including Shaft-Lok® allows us to offer the exceptionally safe and reliable system for virtually any unwind or rewind system. We can combine a standard Shaft-Lok® with CAC brakes for a total unwind solution, or offer custom designs to match any brake, clutch or drive a customer selects," Damour said.

CAC offers rapid deliveries for standard units. According to Damour, Shaft-Lok® systems are competitively priced.

New SimpLok™ Unwind and Rewind Modules

Converter Accessory Corporation (CAC) introduces its new line of unwind and rewind modules. SimpLok™ unwind and rewind modules are the perfect answer where converters want to increase capacity, improve web control, ease roll changes for increased production or for adding unwind or rewind stations to an existing converting machine.

SimpLok shaft holders and unwind / rewind modules are available in standard, medium and heavy duty. They handle rolls from 50 – 5,000 pounds. Unwind and rewind shafts are captured with ball bearings to ensure optimum tension control.

SimpLok modules are available with brake or drive mounting provisions. Lateral adjust with up to +/- 2” of adjustment, skew adjust with up to +/-.5” of adjustment, skew and lateral adjust and edge guide models are available.

All SimpLok systems may be designed with CAC components, such as COR-LOK® air shafts and CAC air operated tension brakes for complete engineered solutions or they may be designed to incorporate other manufacturers’ components. CAC designs these systems to fit customers’ requirements.

According to Jeff Damour, CAC Engineering Manager, SimpLok offers converters an extremely cost effective answer to increasing productivity and product quality. SimpLok unwind and rewind modules provide fast return on investment by improving roll handling and solving many web handling problems.

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	Rollers and Roller Assemblies

How Crowned and Concave Rollers Work

Crowned Spreader Roll

Description:

A crowned spreader roller can be manufactured from a variety of materials, such as steel, aluminum, stainless steel or plated aluminum or steel and can be rubber covered. Although crowned rollers with a rubber surface are the most common, it is not necessary for every application that the surface to be rubber. A crowned spreader roller has an arced surface across its face with the arc sweeping from the ends out toward the center of the roller face. The ends of the roller face are the smallest diameter while the roller diameter increases in equal increments across its’ face to the center. The roller face diameter variance is strictly application dependent. However, it can be generally stated that the bigger the roller diameter, the less the variance. The longer the roller face the more the variance. Extreme variances may be .001” for a large diameter, short face roller and a .100” variance for a small diameter long face roller.

Theory of operation:

By varying the roller diameter across the face of the roller (roller is arced outward across its’ face), tension will vary across the roller face. The increased tension toward the center of the roller will cause tensile stress in the center of the web forcing wrinkles to be pushed out from the center toward the roller face ends.

Recommended wrap angle varies greatly with this type of spreader roller. Typical wrap angles may range between 30° - 180°. Greater degrees of wrap angle will cause greater effect on the web. Spreading may increase with greater amounts of wrap, but the occurrence of web distortion will also increase.

Advantages:

This type of spreader roller has a smooth surface, so it will not mark the surface of a web.
Most any machine shop, rubber roller manufacturer or idler roller manufacturer can machine a crowned roller. This makes this type of spreader roller one of the least expensive, most readily available types of spreader roller.
Simplicity of design, with no special parts makes this spreader roller extremely easy to maintain.
Crowned spreader rollers can be used with all types of materials. The amount of crown depends greatly on the type of web. More extensible materials, like films, will require a minimal amount of crown, where more rigid materials, like paper, will require more amount of crown.

Disadvantages:

The theory of operation for this type of spreader roller is not completely sound. While the tension variance through roller diameter variance is true, the idea of this theory actually spreading the material is unfounded, especially for preventing or removing wrinkles under varying circumstances (see Causes of Web Wrinkles section). An example of this is that while this type of spreader roller may help with wrinkles caused by a baggy center by adding tension to the loose center area of the web, it may worsen the wrinkles caused by baggy edges because the center of the web is already tight. The tightness in the center of the web will only be increased with the use of this roller.
Further reason why this type of spreader may do more harm than good is surface speed variance across its’ face. As this roller rotates, the surface speed at the smaller diameter roller face off center is actually less than in the center (this is the case because the diameter is smaller at the ends than in the center). Slower surface speed toward each end of the roller face can actually drive the web at a slower speed than the center, which will cause the material edges to move in the cross machine direction toward the center of the web (exactly opposite what a spreader roller is supposed to do).
Because this roller is not linear across its’ face (while the web is or should be) it can stretch, distort and/or tear the center of the web.
There is no set formula for the amount of crown for every application, so the amount of crown can only be determined through trial and error or past experience.

Concave Spreader Roller

Description:

A concave spreader roller can be manufactured from a variety of materials, such as steel, aluminum, stainless steel or plated aluminum or steel and can be rubber covered. A concave spreader roller has an arced surface across its face with the arc sweeping from the ends in toward the center of the roller face. The ends of the roller face are the largest diameter while the roller diameter decreases in equal increments across its’ face to the center. The roller face diameter variance is strictly application dependent. However, it can be generally stated that the bigger the roller diameter, the less the variance. The longer the roller face the more the variance. Extreme variances may be .001” for a large diameter, short face roller and a .100” variance for a small diameter long face roller.

Theory of operation:

By varying the roller diameter across the face of the roller (roller is arced inward across its face), surface speed will vary across the roller face. The increased surface speed toward the edges of the roller will cause wrinkles to “walk” out from the center toward the roller face ends.

Advantages:

This type of spreader roller has a smooth surface, so it will not mark the surface of a web.
Most any machine shop, rubber roller manufacturer or idler roller manufacturer can machine a concave roller. This makes this type of spreader roller one of the least expensive, most readily available types of spreader roller.
Simplicity of design, with no special parts makes this spreader roller extremely easy to maintain.
Concave spreader rollers can be used with all types of materials. The amount of concave profile depends greatly on the type of web. More extensible materials, like films, will require a minimal amount of concave profile, where more rigid materials, like paper, will require more amount of concave profile.

Disadvantages:

While the theory of operation for this type of spreader roller is sound. It may not work or it may even compound certain wrinkling conditions. An example of this is that even though this spreader roller relies on surface speed differential across its’ face (not tension variation, as in the case of the crowned roller) to spread the web, tension variations will occur across the web because the roller face is not linear. This roller will probably perform well for baggy edges type wrinkles – the roller diameter being larger toward the roller face ends adding tension to the loose edges. It could compound the problem for baggy center type wrinkles – the roller face profile worsening the looseness in tension, in the center of the web.
Because this roller is not linear across its’ face (while the web is or should be) it can stretch, distort and/or tear the edges of the web.
There is no set formula for the amount of concave profile requirement for every application, so the amount of concave profile can only be determined through trial and error or past experience.

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Written By: Jeff Damour

Nip Roll Modules for Web Handling

CAC now designs and manufactures both standard and custom precision, air loaded nip roll modules. These air loaded nip modules allow precise side-to-side gap adjustment, independent of precise pneumatic pressure adjustment. They can be supplied as non driven or with complete drive systems. All feature plate steel framework and may be supplied with either dual side frames or cantilevered for narrow width applications.

CAC nip roll modules have proven to be effective with all types of webs, including film, foil, paper, textiles and nonwovens. Typically they are used where independent tension zones are required. However, they are also utilized in laminating, coating and calendaring applications.

Nip modules are designed to be easily placed in existing machinery or engineered as part of a new machine build. Nip rolls are available with many types of coatings including chrome, plasma, nickel and Teflon. Rubber coverings, including silicone, neoprene, EPDM, urethane and others are also available. Roll materials may be ordered in aluminum, steel or brass. Finishes can range from ground mirror finish to course knurls. Roll diameters from 1" to 18" and roll faces from 3" to 120" are available.

CAC’s electrically heated roll, model EHR, may be incorporated in the nip roll module to facilitate web heating. They may also be combined with CAC’s rotational type dancer rolls to control web tension entering and / or exiting the nip module.

Jeff Damour, Engineering Manager said, "We are delighted to offer our customers a broad array of nip module configurations with extensive roll coverings and configurations available. All our precision, air loaded nip roll modules are designed to be readily retrofitted to virtually any converting operation as single upgrade components or as part of an overall web handling package. We take pride in designing these modules for efficient, smooth installations."

Founded in 1974, Converter Accessory Corporation designs, engineers and manufactures web handling equipment for converters of paper, film, foil, nonwovens and textiles. Engineered solutions include high quality, cost effective equipment for narrow web to wide web, slow speed to high speed, prototyping to full production applications. CAC is represented by knowledgeable engineering staff and provides extensive consultation and unparalleled product support.

CAC Idler Options Now Include Winertia™

CAC is now offering idler rolls featuring patented Winertia ™ engineered profile aluminum tubing specifically designed and engineered for idlers used in the converting industry.

CAC idler rolls are available with standard outside diameters of 3”, 4”, 5”, 6” and 8”. Special diameters are also available. Face widths are available up to 140”. Standard roll finish is 30 Ra. Various roll coatings/coverings are available in rubber, Teflon, plasma, anodize, chrome, and nickel. Grooved roll face is also available in many standard and custom machined profiles.

CAC idlers are supplied with low friction bearings, improving web handling by maximizing web traction with the idler roll face. They are available in both dead shaft (center shaft fixed) and live shaft (journals rotate with roll face) construction. Rolls are dynamically balanced to minimize vibration. Roll faces are machined to maximize concentricity. Optional mounting blocks and bearings are available for both types.

Materials available for idler roll construction are steel, aluminum, stainless steel and Winertia™. According to Jeff Damour, CAC engineering manager, Winertia™ engineered profile aluminum tubing for idlers offers customers performance superior to that of any other idlers employing aluminum tubing. Benefits include lower weight, which translates to 10-30% less rotational inertia and momentum, improving web traction with the idler roll face, which improves web handling and behavior, Winertia™ also allows us to better position support bearings or supply dual bearing supports to minimize roll face deflection. Unique 3D balancing contributes to better roll performance. The result is faster, smoother operation that cannot be achieved with conventional aluminum tubing.

Damour said, “When we combine CAC engineering know how with the proven performance of Winertia™ tubing, the result is a reasonably priced idler that offers unequalled performance. Our customers expect us to be experts on web handling and alert to new technologies that offer the best possible performance.”

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	Brakes

Tension Air Brake Easily Integrates for Smooth Unwind Upgrade

CAC’s newest Tension Air Brake (TAB) is engineered to be reliable, versatile and exceptionally easy to use. It is specifically designed to be easily employed with CAC’s widely used ShaftLok™ safety shaft holders for a complete unwind upgrade, but may also be integrated with less advanced, traditional shaft holders.

The TAB offers a broad torque range, excellent heat dissipation and operates on plain air. It can be operated manually via a simple pressure regulator or readily combined with an automatic tension control system. TAB has three friction coefficients to choose from and is available in 2, 4, 6 or 8 friction pad engagement configurations for a proper, custom torque match to individual setups.

Jeff Damour, CAC Engineering Manager, says the TAB is distinguished by an elegantly simple design that makes it especially easy to implement and operate.

“We apply everything we’ve learned over three decades to every web enhancement product we offer. All components, even the most basic, are carefully engineered and meticulously fabricated to fit smoothly into our building block approach to web handling,” Damour said.

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	Roll Support System

Grooved Rollers for Wrinkle Removal

escription:

A grooved spreader roller can be manufactured from a variety of materials, such as steel, aluminum, stainless steel, plated aluminum or steel and hard rubber. A rigid grooved spreader roller has grooves machined into the roller face surface. These grooves (resembling screw threads) are machined – starting from the center of the roller and leading out to each edge of the roller face. The grooves can be supplied in almost any fashion; from as simple as wrapping masking tape across the face of a standard idler roller to a machined groove that has very intricate machining details. Groove design is completely application dependent, however it can be generally stated that the greater the number of groove starts there are the greater the spreading will be realized.

Theory of operation:

Quite simply the theory is that the grooves will push wrinkles out of the web, from the center out to each edge, which, unfortunately is not always the case (see advantages and disadvantages, below).

Recommended wrap angle for this type of spreader roller normally ranges between 90° - 180°.

Advantages when applied as an idler roller:

This type of spreader roller will remove air when air entrainment is a problem (this in itself will help to remove or prevent wrinkles).
Depending on the groove design, these rollers can often be manufactured by most machine shops, rubber roller manufacturer or idler roller supplier. Making this type of spreader one of the least expensive, most readily available types of spreader roller.
Simplicity of design, with no special parts, makes this spreader roller extremely easy to maintain.
Because this roller is linear across its face, it will not stretch, distort or tear any portion of the web.
This type of spreader roller is best suited for use with textiles and non-wovens. It has limited application with papers, foils and films.

Disadvantages when applied as an idler roller:

When this spreader is applied as an idler roller (driven at the surface speed of the web), the grooves do not push wrinkles out from the center of the roller face (even though this is most often believed to be the case). When the surface of the grooved roller is driven at the same speed as the surface of the web (such is the case when used as an idler roller) the tangent point, at any given point across the web or roller face, where the web first touches the roller remains in a constant position through the roller rotation. Because the tangent point of the web lying on top of the groove does not vary, the groove has no cross machine direction movement effect on the web. The belief that the grooves have some effect on the web is mostly an optical illusion (like the illusion caused by a rotating barber shop pole). An engineer once told me an excellent analogy of the non-effect of the grooves on the web in this application (I can’t take credit for the analogy); if you place a plow in a field, does the field plow itself by the rotation of the earth? Of course not, and the reason is because the tangent point of the plow in the field remains constant with the earth in its rotation.
This type of roller does not have a smooth surface so it has the potential to mark the web surface.
Some materials may deform across the web face and the groove will actually form in the profile of the web causing wrinkles.

Advantages when used as a “dead bar” or driven slower or faster than the web:

All the advantages as an idler roller plus one more.
When the surface speed of this type of roller is not synchronized with the web speed (standing completely still is included here) then we get a different level of performance with this type of roller. When this is the case, the grooves will push the web outward toward each edge of the roller face. This effect occurs because the tangent point where the web touches the roller face is ever-changing as the web travels around the circumference of the roller. The changing position of this tangent point ensures that the web, at that point, will travel in the direction the groove is facing.

Disadvantages when used as a “dead bar” or driven slower or faster than the web:

Web marking and scratching will occur much more frequently than with spreader rollers that rotate, at the same rate, with the web.
When there is speed differential between the roller face and the web, the web is not in traction with the roller. For this reason the web position can vary across the roller face causing edge guiding and possibly wrinkling problems down-line of this spreader roller.

Grooved Roller – Soft Flexible Rubber

Description:

A soft flexible grooved roller can be manufactured from different types of rubber compounds, but what is most important is that the rubber is soft enough to flex under the pressure of the web tension. The flexible grooved roller has grooves machined under its’ surface. The grooves must be precisely spaced. The groove depth is varied across the roller face, as the grooves move out from the center of the roller, they get deeper. This depth variance is even across the face of the roller and must be accurately controlled.

Theory of operation:

As this roller rotates with the same surface speed as the web, it has flexible lands (created by grooves machined into the surface of the soft rubber face), which deflect under the webs tension. The lands deflect in the direction they are angled, from the center out to each edge of the roller face. The depth of the grooves increases from the center out to each edge of the roller face. The reason for the depth adjustment out to each edge of the roller face is so each land will flex more than the land next to it, ever increasing from the center of the roller. The difference in flex amount between each land is important because it provides for web spreading between each land. In other words if all the lands flexed exactly the same amount, spreading would be achieved only in the center of the web, there would be no spreading from land to land.

Recommended wrap angle for this type of spreader roller is strictly application dependent and can vary between 30° to 180°

Advantages:

This type of spreader will remove air when air entrainment is a problem. This will help keep the web in traction with this roller improving its’ operation.
Because this roller is linear across its face, it will not stretch distort or tear any portion of the web.
Because of its soft surface, this roller will not mark or scratch the web.
This type of spreader is used with all types of webs.

Disadvantages:

While the lands do flex under the pressure of the tension on the web, they will return to their natural position as the pressure is being relieved. The pressure is relieved as the web exits the roller. As the lands flex back to their natural position, some of the wrinkles the roller removed may return.
This roller does not have a smooth surface, so some webs may deform inside the groove, taking on the profile of the groove.

This type of spreader roller has no wrap angle. Because the web is not supported across its full width, the material must be fed straight in and out of this spreader roller assembly.

Advantages:

This type of spreader roller is the most aggressive.
Simplicity of design makes this type of spreader roller easy to maintain.
The amount of spreading is easily adjustable, by changing the angle of each nip set independently of each other.
Works well with woven and non-woven webs.

Disadvantages:

Because this spreader roller will not support the web across its full width, it will mark, distort and possibly tear most foils.
This type of spreader roller is specifically designed for woven and non-woven materials. Any other type of materials may have difficulty with this type of spreader roller, because of web distortion.

Written By: Jeff Damour

New Dual Station Scrap Rewind System Offers Exceptional Efficiency

Converter Accessory Corporation (CAC®) is introducing a new dual station system (SW2) that allows on-the-fly cutover with minimal to zero stop time. The SW2 is engineered for web widths to 30 inches and capable of rewinding rolls up to 36 inches in diameter in weights to 600 pounds. A robust drive delivers speed ranging from fractional to 1000 feet per minute. The complete, belt driven system is supplied with a torque controlled motor with manual control, digital torque setting and emergency ”stop“function.

The SW2 will readily accommodate automatic tension control if desired.

According to Jeff Damour, CAC® Engineering Manager, the SW2 is ideal for rewinding edge trim and label matrix scrap and is much faster than single station systems. While aimed at scrap rewind, the SW2 may also used for any rewinding application that fits the SW2's capabilities.

”Like all CAC systems, the SW2 is engineered for easy operation, easy maintenance and easy installation. It can be installed on a machine frame, table top or floor mounted. The belt drive is designed for reliable, quiet operation,“ Damour said.

The SW2 features CAC's widely used COR-LOK air shafts for fast, easy core locking and rapid roll changes.

In addition to the SW2, CAC offers a wide range of unwind and rewind technology optimized by CAC's unique ”building block“ approach. This approach begins with two basic pedestals to which any or all of CAC's web handling accessories can be added; including core support systems, shaft support systems, pneumatic conveying systems and wrinkle removal systems.

Drawing on the experience of more than 30 years of success, Converter Accessory Corporation designs, engineers and manufactures web handling equipment for converters of paper, film, foil, nonwovens and textiles. Engineered solutions include high quality, cost effective equipment from the simplest aluminum core cone to the most sophisticated unwind/rewind system. CAC is represented by knowledgeable sales engineers and provides extensive consultation and post sales support.

For more information contact Pam Damour, Converter Accessory Corporation, 201 Alpha Road, Wind Gap, PA 18091-1279, (800) 433 2413, fax (610) 863 7818. CAC@epix.net Web site: www.handleyourweb.com

Modular Rewinds and Unwinds Allow Easy Increased Production and Added Capabilities

Wind Gap, Pennsylvania: CAC's latest single station and multi station unwind and rewind systems are engineered as modular technology allowing them to be easily integrated into existing lines. Among the benefits offered by CAC unwinds and rewinds are that they allow processors to easily and economically add a station and increase production, expand capabilities and reduce changeovers by allowing larger rolls.

According to Jeff Damour, CAC Engineering Manager, CAC unwinds and rewinds can be custom configured using off the shelf components and may be as simple or as sophisticated as the customer's application requires. They are exceptionally competitively priced competitive, are usually delivered and installed very quickly and are compatible with all web production materials.

CAC offers an exceptionally broad range of sizes and capabilities, including manual and automatic controls. Rolls can be handled at up to 2000 fpm in diameters to 60 inches and web widths to 120 inches and weights to 3000 lbs. For wider web applications, stand alone systems are the preferred choice. Machine mounted systems are available for narrow web operations and are offered in a wide range of simple to sophisticated systems.

”The benefits of our unwinds and rewinds are extraordinary. With a simple installation we can allow a converter to develop an entirely new process, such as laminating, for example. The modular construction designs made possible by our decades of experience in virtually all types of web operations make these systems an unusually cost effective solution to a converter's desire to grow without investing in a major overhaul. It is precisely the kind of technology converters tell us they are looking for-effective, easy to install, easy to maintain,“ Damour said.

CAC unwind and rewind options include single and multi-station in dual support pedestal and cantilevered configurations. CAC unwind and rewind stands feature compact designs to minimize floor space requirements and are heavy-duty; constructed of structural steel for maximum strength and rigidity. All systems are engineered to be readily retrofitted to existing lines and to seamlessly incorporate the full range of CAC web handling technology including air shafts, and safety chucks.

A typical custom configured CAC unwind/rewind system may include a wide range of CAC supplied options, including closed or open loop automatic tension control, web guide systems, COR-LOK® air shaft featuring exceptional gripping power, Shaft-Lok safety chucks, and idler rolls featuring Winertia® engineered aluminum tubing.

Currently celebrating its 31st year of success, Converter Accessory Corporation designs, engineers and manufactures web handling equipment for converters of paper, film, foil, nonwovens and textiles. Engineered solutions include high quality, cost effective equipment from the simplest aluminum core cone to the most sophisticated unwind/rewind system. CAC is represented by knowledgeable sales engineers and provides extensive consultation and post sales support.

For more information contact Pam Damour, Converter Accessory Corporation, 201 Alpha Road, Wind Gap, PA 18091-1279, (800) 433 2413, fax (610) 863 7818. CAC@epix.net Web site: www.handleyourweb.com

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	Trim Removal System

How to Get the Most from Your Venturi Based Trim Conveying System

Venturi type pneumatic trim conveying systems, like CAC's FOX TrimAway systems are an excellent choice for efficient, reliable and cost effective edge trim waste handling. These types of edge trim conveying systems use a blower to power a specialized venturi, which generates suction to capture and pressure to convey edge trim waste. Some things to consider to get the most from your venturi based pneumatic trim removal system:

Keep intake distance to a minimum. Intake duct is the total amount of duct on the suction side of the venturi. There is far more air flow on the discharge side of the venturi, typically twice the suction side. Short intake distance gets the trim to the most powerful portion of the system in the least amount of space.

Ensure the blower pressure, powering the venturi, is operating at the highest possible pressure. Check for leaks and decrease bends in the duct powering the venturi.

All duct work bends should be long sweeps. Sharp elbow type bends create restriction and stop the easy flow of the edge trims through the system.
A change in operating specifications (machine speed, trim width, conveying distance) may require system changes to operate properly.

Always check blower amperage at initial setup of the system to make sure the blower is operating within its' proper range.
Most venturi's are adjustable if the system is under powered or overpowered for your application. Always follow manufacturers instructions for venturi adjustment.

Most blowers, as supplied with FOX TrimAway systems, can be controlled with variable frequency drives (VFD). Controlling with a VFD can increase efficiency and decrease overall power consumption.
Use Teflon coated components and duct for applications where exposed adhesive is a concern to eliminate duct clogs.

Check suction filters regularly to insure blower efficiency.

Properly designed, sized and maintained venturi based trim removal systems will provide years of reliable service.

Join the conversation

Written By: Jeff Damour

A Look Inside Our Pneumatic Matrix Removal Systems

FOX TrimAway® pneumatic matrix waste conveying for anyone printing, die cutting and converting labels. Perfect for recycling efforts. FOX TrimAway pneumatic matrix conveying provides fast return on investment for anyone working with labels. Here's and inside look at how CAC's FOX TrimAway pneumatic matrix conveying system works!

Click here to read more!

Trim-AX™ Heavy Duty Chopper

The industry's best, most reliable chopper

Will chop very thin (.0005”) to very thick and heavy (.5”) materials
Easily integrated into your existing pneumatic waste removal system
Decrease waste bulk
Teflon coating available
Convey trim longer distances
Silencers available
Heavy duty
Built to last
Designed for use with CAC's FOX TrimAway Systems
Stable and quiet
3,450 Cuts per minute (variable speed available)
Inlet and outlet transitions available for common duct sizes
Made in the USA!

Flexible, easy to install, easy to use, efficient pneumatic waste conveying

Unique venturi design for powerful, adjustable, efficient waste removal
Never slow down to accommodate your waste
Run your machine faster
Modular design ensures hassle free operation
0.5 Horsepower to 20 Horsepower; 3 venturi sizes to choose from
Whisper quiet
Discharge distances over 250 feet
FOX TrimAway utilizes super energy saving regenerative blowers
Long maintenance free life
Easily handle adhesives without oil or powder injection
Edge trims over 6” speeds over 6,000 FPM
Full test facility – we will test your waste with the appropriate FOX TrimAway system and email you a video
Trim-AX trim choppers – the industries best, most reliable chopper – available
Various waste collection methods available
Portable systems
Complete turn-key systems
Individual components (venturis, blowers, pickup nozzles, Ys, duct work and much more)
Systems and components in stock ready for quick shipment - click here!
Made in the USA!
Click here for additional information!

FOX TrimAway has been part of CAC’s family of products since 1987 ; thousands of successful applications here and abroad.

Compressed Air vs. Regenerative Blower

Looking for new ways to cut costs?

One place to look is at your trim or scrap removal system. A very popular method of modular trim/scrap removal system includes a venturi which uses compressed air to operate. The attraction of this type of venturi system is its initial low cost. These venturis are very simple, small and relatively easy to manufacture, so the initial cost of the venturi itself is very low. Since this type of venturi uses compressed air to operate, there is no external power source (blower) to purchase, so again initial cost is kept low.

Seem too good to be true? It is. While the initial cost of these types of modular trim/scrap removal systems will keep your purchasing department happy, long term costs will negate and surpass your savings.

Compressed air is designed to operate equipment which requires very high pressure, very low volume. As a rule of thumb, it is never advisable to exhaust compressed air into atmosphere, which is exactly what you’re doing when you use this type of venturi trim/scrap removal. Why? Because compressed air volume is very expensive in energy consumption and maintenance when compared to blower air volume. Also, other areas of your plant operation may be negatively effected downstream of a venturi compressed air system that strains the compressor, dumping valuable compressed air into the atmosphere.

Use a venturi trim/scrap removal system which utilizes a blower to avoid the yearly energy and maintenance costs of over using your air compressor. Venturi systems which utilize blowers cost more initially but the savings, over time, of relieving your air compressor of the responsibility of powering the system will most likely more than pay for the venturi/blower system in less than one year. In some cases, savings are around $10,000 in a single year.

Edge Trimmer/Chopper on the go

A combination of venturi-based trim remover and high-output chopper in a single pre-wired and moveable frame was developed by CAC. Called Fox Combo, it can be installed and used within minutes and moved within a plant. It uses either a 5.5, 10 or 15 hp Fox TrimAway venturi blower system with a recently developed TrimAX 2-blade chopper, capable of 3,200 cuts/min. of film, sheet or carpet edge trim up to 6 inches wide, running up to 3,000 ft/min. The combo has two starters, so the venturi can also run alone, bypassing the chopper. The first was delivered in March. Eight months ago CAC also began to offer its TrimAway venturi in a moveable frame, calling that the FoxRunner.

New Integrated Trim Removal and Chopper System

CAC® is introducing the Fox Combo™, a new, factory assembled, combination trim removal and chopper system that ships as a single complete unit. The Fox Combo™ combines the widely employed, venturi-based Fox TrimAWAY® with CAC’s recently introduced TrimAX™, a two bladed chopper capable of 3,450 cuts per minute. The two systems are both mounted on a sturdy, but moveable framework and are designed to be used together or independently.

The Fox Combo™ system is designed for the 5 1/2 to 15 horsepower, FX2 and FX3 Fox TrimAWAY® systems. These systems handle materials from 1/2 mil to heavy carpet in widths to 6 inches at speeds to 3000 feet per minute. The entire system can be moved from one production line to another with a power jack.

According to Jeff Damour, CAC Engineering Manager, the Fox Combo™ is especially adept at chopping and moving bulky trim waste material to a waste collection point.

”This is a versatile system built in response to customers requests for a single Fox type unit with a compatible, mounted chopper for handling a variety of materials, especially heavy paper trim waste,“ Damour said.

CAC® offers 30 standard Fox systems with blowers from 1-horsepower to 15-horsepower. All components are engineered to match each customer’s specifications. Components include a unique, adjustable Venturi, Gast® Regenerative Blower, pickup nozzle, Y connectors, collection centers, flexible ducts, motor starters, trim choppers, filters and silencers if needed.

For Label Converters, New Portable Matrix Trim Removal System Enhances Production, Reduces Material Costs

Converter Accessory Corporation (CAC®) announces the portable trim removal system FOX Runner® is now available in a new size, the FX1.5. The FX1.5 fills an important niche in the previously very wide gap between the small FX1 and the exceptionally powerful FX2.

The portable FOX Runner® FX1.5 can handle up to 2 inch wide trim at speeds to 2000 feet per minute, while the larger FX2 can run at speeds to 6000 fpm. In installations where 2000 fmp is an optimal speed, the FX1.5’s small size contributes to its unobtrusive installation in locations that would not accommodate a larger system and also offers more energy efficiency.

”Most importantly,“ Jeff Damour, CAC® Engineering Manager said, ”there is a large jump in price between the FX1 and FX2 and the FX1.5 is a cost effective alternative that should prove very attractive, especially to OEM’s.“

The FOX Runner® uses CAC’s® widely employed FOX TrimAway® pneumatic trim removal components mounted to a portable stand for permanent, semi permanent and temporary applications.

The complete FOX Runner® portable system includes CAC’s® exclusive venturi design; a regenerative, exceptionally quiet, virtually maintenance free blower; all the blower hardware, motor starter plug and cord, blower filter. Additionally, the system includes pick-up nozzle(s) and Y connectors; 10-foot standard intake and discharge ducts with high torque duct clamps; complete welded tubular steel system mounting frame and locking casters. Options include collection units such as high-capacity nylon bags and metal collection bins, and discharge ducts over 100 feet long.

FOX Runner® systems are designed to handle trim widths ranging up to 2 to 6 inches at speeds up to 6000 feet per minute. The FOX Runner® is engineered to efficiently remove paper, film, foils, textile and non-woven trims. It is especially effective with more difficult to handle die cutter waste as well as chopped, granulated and pelletized materials.

What distinguishes the FOX Runner®, according to Jeff Damour, CAC® Engineering Manager, are a high-speed production, versatility, energy efficiency, low maintenance and easy installation.

”It is stable enough to put in place for long term trim handling or it can be easily wheeled to multiple locations throughout a plant and rapidly set up and put to work wherever it is needed,“ Damour said. rdquo;In many cases the Fox Runner’s portability can save converters the need to purchase multiple systems.“

The FOX Runner® can be readily integrated with most plastics recycling equipment for a complete, seamless and profitable waste reclaim system.

All FOX TrimAway® systems are designed to be exceptionally easy to install and easy to operate. They are quiet, frugal consumers of electricity, especially when compared to systems that rely on energy gobbling compressed air. All Fox systems feature modular constructions sized to customer production requirements. CAC® offers Fox technology in over 30 standard systems.

Portable New Trim Removal System Size Fills Important Niche

FOX Runner®, Converter Accessory Corporation’s (CAC) exceptionally popular portable pneumatic trim removal system is now available with CAC’s new variable speed blower control. This combination allows for the ultimate in energy efficient pneumatic trim removal.

According to Jeff Damour, Engineering manager, “The portability of FOX Runner allows it to be used where ever it will have the most impact in your plant. Now, combined with CAC’s new variable speed blower control, FOX Runner offers the ultimate in energy savings and convenience for pneumatic trim removal”.

The FOX Runner is stable enough to put in place for long term trim handling or it can be easily transported to new locations and rapidly set up and put to work. In many cases FOX Runner’s portability can save converters the need to purchase multiple trim removal systems.

FOX Runner uses CAC’s long time successful FOX TrimAway® pneumatic trim removal components mounted to a portable stand for permanent, semi-permanent and temporary applications. It is offered as a complete, turnkey system that can be readily and quickly integrated in any trim removal application.

FOX Runner portable systems include CAC’s exclusive venturi design, a regenerative blower, blower hardware and filter, motor starter with plug and cord. Additionally, the system includes pick-up nozzles, Y connectors, duct work and high torque duct clamps. All FOX components are mounted to a tubular steel frame with locking caters. Optional components available are collection bags and bins, silencers and additional duct for long conveying distances.

“Today, energy savings has never been more important to our customers”, says Jeff Damour, CAC Engineering Manager. “The ability to vary blower speed allows our customers to optimize the energy efficiency of Fox TrimAway, while maintaining the proper performance for any trim removal application. Bottom line, the ability to ‘customize’ the blower speed to match a specific trim removal requirement for a specific machine run will save energy and save our customers energy dollars.”

The soft starting feature built in to these VSD’s will start the blower motor with a smooth, linear acceleration of a programmed time. The advantage when compared to standard blower starters is there is no sudden inrush of current that puts large demand on power lines. Soft starting eliminates stress on electrical and mechanical components. Maintenance costs are reduced and lifetime of system blowers extended. High starting currents and voltage dips in the supply network, which might cause process disturbances, are eliminated.

Designed to handle trim widths up to 4 inches at speeds up to 3,000 feet per minute, FOX Runner will include the proper components to handle your needs. FOX Runner will efficiently remove paper, film, foil, textile and non-woven webs. They are designed to be exceptionally easy to operate, quiet and frugal consumers of electricity.

Converter of Wide Range of Materials Improves Efficiency with New Trim Removal System

Minneapolis, Minnesota: Litin Paper Company, Minneapolis, Minnesota, a seasoned, family owned company with years of converting, experience turned to Converter Accessory Corporation (CAC®), Wind Gap, Pennsylvania, also a family owned company with decades of experience, for a portable system able to efficiently remove large amounts of trim from several production lines.

In business since 1947, Litin is a converter and wholesale distributor of packaging and industrial supplies. With 32 employees the company operates six converting lines performing cutting, slitting and rewinding in both small and wide diameters. Production includes sheeting, producing packaging paper counter rolls, butcher paper, plotter paper, wax coated paper, silicone coated paper, and newsprint.

With so many products diverse in gauge and weight, Litin needed a versatile system, one able to handle the heavy kraft trim as well as the very light thin gauge papers and plastics.

According to John Hanson, Litin Vice President/General Manger, handling trim waste, while in itself not a major problem, was a nagging annoyance made worse by Litin’s rapid growth rate.

”We wanted a way to efficiently collect diverse trim materials and move them easily from a production line to a collection area. We wanted the solution to be priced to fit our budget, easy to install and maintain and able to be moved from line to line, where needed“ Hanson said.

After a thorough search Litin contacted CAC and became convinced that the Fox Runner™ version of the widely used Fox TrimAway® system was the best option and ordered an FX2-700R, capable of pneumatically moving trim up to a hundred feet.

The Fox Runner™ uses CAC’s widely employed Fox TrimAway® pneumatic trim removal components mounted to a portable stand for permanent, semi permanent and temporary applications.

The complete Fox Runner™ portable system includes CAC’s exclusive venturi design; a regenerative, exceptionally quiet, virtually maintenance free blower; all the blower hardware, motor starter plug and cord, blower filter. Additionally, the system includes pick-up nozzle(s) and Y connectors; 10-foot standard intake and discharge ducts with high torque duct clamps; complete welded tubular steel system mounting frame and locking casters. Options include collection units such as high-capacity nylon bags and metal collection bins, and discharge ducts over 100 feet long.

Fox Runner™ systems are designed to handle trim widths ranging up to two and six inches, at speeds up to 6000 feet per minute, depending on the Fox system size. The Fox Runner™ is engineered to efficiently remove paper, film, foils, textile and non-woven trims. It is especially effective with more difficult to handle die cutter waste as well as chopped, granulated and pelletized materials. According to John Hanson, the Fox Runner™ was easy to install and delivered the versatility, energy efficiency, and low maintenance that Litin required. ”It is stable enough to put in place for long term trim handling or it can be easily wheeled to multiple locations throughout the plant and rapidly set up and put to work wherever it is needed,“ Hanson said. ”And finally,“ he added, ”It works great. And it’s quiet! We especially appreciate that.“

New Trim-AX™ Heavy Duty Dual Bladed Chopper

Converter Accessory Corporation’s (CAC®) new Trim-AX™ chopper for chopping nearly every type of web waste trim materials is a two bladed unit capable of 3,450 cuts per minute with a 1,725 rpm motor. It features variable speed control. Thanks to extra heavy duty construction, with a dual bearing support, the system is exceptionally stable and runs quietly. Rotating blades are easily changed and are readily available from CAC®.

Trim-AX™ has proven capable of handling materials ranging from heavy carpet to very light, 1/2 mil thick materials, including paperboard, paper, nonwovens PE, and nylon. It has proven especially effective reclaiming carpet edge trim, cutting it into sizes that allow easy transportation through a blower based venturi system.

Now offered as a separate component, Trim-AX™ was originally designed to work smoothly with CAC’s family of Fox TrimAWAY™ trim removal systems. The Trim-AX™ can easily be integrated to enhance operation of most venturi air conveying waste removal systems.

According to Jeff Damour, CAC® Engineering Manager, CAC’s Fox systems do not need a chopper to be effective. However, the Trim-AX™ can allow an air conveyor system to work over longer distances, over 200 feet with a Fox system, for example. The Trim-AX™ also makes waste handling more efficient and chopped trim takes less space in collection bins.

”Customers told us they were not satisfied with the choppers that were available. They asked us to find the best option and after examining the possibilities, we decided to design and build our own. Converters who are looking to blow trim longer distances, have limited storage space, or who want size reduced trim for reprocessing efficiency should give careful consideration to the Trim-AX™. It’s an exceptionally well designed unit and is built to last,“ Damour said.

The Trim-AX™ is an optional component of CAC’s large offering of Fox trim removal systems. CAC offers 30 standard systems with blowers from 1-horsepower to 15-horsepower. All components are engineered to match each customer’s specifications. In addition to the Trim-AX™ components include a unique, adjustable Venturi, Gast® Regenerative Blower, pickup nozzle, Y connectors, collection centers, flexible ducts, motor starters, filters and silencers if needed.

Damour said, rdquo;We deliver a complete, ready-to-work trim removal system fully supported by readily available spare parts. When customers ask for a new technology or solution, we do our best to bring what they ask for to market promptly.“

Exceptionally Popular Portable Trim Removal Reduces Waste and Labor

FOX Runner® , Converter Accessory Corporation’s (CAC®) recently introduced, portable system for trim removal, is proving to be extraordinarily successful.

Reduces Waste

Jeff Damour, CAC Engineering Manager, attributes the demand to converters concerned about unstable material prices searching for effective ways to cut costs. FOX Runner eliminates the need to wind trim and allows converters to run the narrowest trim possible without the well known difficulties of maintaining a thin width trim roll. The result of trim width reduction is less waste.

Damour said, ”Considering how fast today’s converting webs run, efficient removal of ultra thin trim can allow significant material costs. The efficient, easily operated FOX Runner also allows labor savings and reduced down time.“

Ease of Movement Can Reduce Need for Multiple Systems

In a multi web plant, the portability of the FOX Runner allows it to be used wherever it will have the most impact. The FOX Runner is stable enough to put in place for long term trim handling or, if a line is down for repairs or maintenance, for example, it can be easily wheeled to new locations throughout a plant and rapidly set up and put to work wherever it is needed. In many cases the FOX Runner’s portability can save converters from the need to purchase multiple systems.

The FOX Runner uses CAC’s long time successful FOX TrimAway® pneumatic trim removal components mounted to a portable stand for permanent, semi permanent and temporary applications. It is offered as a complete, turnkey system that can be readily and quickly integrated with a running web.

Complete Turnkey System

The complete FOX Runner portable system includes CAC’s exclusive venturi design; a regenerative, exceptionally quiet, virtually maintenance free blower; all the blower hardware, motor starter plug and cord, blower filter. Additionally, the system includes pick-up nozzle(s) and Y connectors; 10-foot standard intake and discharge ducts with high torque duct clamps; complete welded tubular steel system mounting frame and locking casters. Options include collection units such as high-capacity nylon bags and metal collection bins, and discharge ducts over 100 feet long.

FOX Runner systems are designed to handle trim widths ranging up to 1 to 4 inches at speeds 100 to 3000 feet per minute. The FOX Runner is engineered to efficiently remove paper, film, foils, textile and non-woven trims. It is especially effective with more difficult to handle die cutter waste as well as chopped, granulated and pelletized materials.

The FOX Runner can be readily integrated with most plastics recycling equipment for a complete, seamless and profitable waste reclaim system.

All FOX systems are designed to be exceptionally easy to install and easy to operate. They are quiet, frugal consumers of electricity, especially when compared to systems that rely on energy gobbling compressed air. All FOX systems feature modular constructions sized to customer production requirements. CAC offers FOX technology in over 30 standard systems.

Portable Trim Removal System Features High Speed Production

Introducing the FOX TrimAway® and the FOX Runner® systems engineered for efficient trim removal during production or converting of most web materials including, paper, film, foil, board, nonwovens and textiles. It is effective with trim ranging from 1/16“ to 6“ widths and can operate at speeds up to 4000 feet per minute.

The venturi-based FOX TrimAway® system includes a Gast® Regenerative Blower and a unique, adjustable venturi. It transports waste to any waste collection point and can be integrated with recycling equipment. The system can operate as a single installation or as a coherent system consisting of several FOX TrimAway® systems. A complete CAC® FOX TrimAway® system includes all required parts and components needed to begin efficient trim removal.

The versatile FOX Runner® is a portable version of the FOX TrimAway® that can be quickly engaged and disengaged and easily rolled, on built-in wheels, from one production line to another, as needed.

The FOX TrimAway® system is especially advantageous when employed for removal of difficult to wind narrow trim widths and thin gauge products. In such applications, FOX TrimAway®: systems have paid for themselves very quickly by freeing manufacturers from the need to product waste in wider than necessary, easily wound widths, according the Jeff Damour, CAC® Engineering Manager.

”We have customers who reduced their edge trim from a width of several inches to a fraction of an inch. It doesn't take very long for reduction of a few inches of web width to add up to major savings,“ Damour said. ”Many customers claim to have paid for the FOX TrimAway®: in less than six months.“

FOX TrimAway® systems are designed to be exceptionally easy to install and easy to operate. They are quiet, frugal consumers of electricity, especially when compared to systems that rely on energy gobbling compressed air.

”Energy efficiency is derived in part from not requiring a compressor. Being compressor free also contributes to the quiet operation of the FOX TrimAway®. Though we offer silencers, the system, without silencers, is complete OSHA compliant,“ Damour said. All FOX TrimAway® systems are modular constructions sized to customer requirements.

CAC® offers 30 standard systems with blowers from 1 horsepower to 15 horsepower. All components are engineered to match each customer's specifications. Components include a unique, adjustable Venturi, Gast® Regenerative Blower, pickup nozzle, Y connectors, collection center, flexible ducts, motor starters, trim choppers, filters and silencers if needed. In short, Damour says, we deliver a complete ready-to-work trim removal system fully supported by readily available spare parts.

New Trim Removal - reduces waste

Are you considering modifying or replacing existing slitting equipment? If you are, it is always a good idea to send samples to your potential slitting equipment supplier.

Generally speaking, slitting equipment suppliers have some amount of testing equipment at their facility. They can run your samples (even if it is just hand feeding them into a slitter) which will help to determine the best slitting solution for your web and process.

When sending samples to a supplier make sure to send samples of all of the webs you will potentially run in your process. The slitting equipment supplier may recommend one or more slitting methods base solely on the samples they have in hand.

Be very careful of selecting a slitting system for which samples have not been tested.

Converter of Wide Range of Materials Improves Efficiency with New Trim Removal System

Litin Paper Company, Minneapolis, Minnesota, a seasoned, family owned company with years of converting, experience turned to Converter Accessory Corporation (CAC), Wind Gap, Pennsylvania, also a family owned company with decades of experience, for a portable system able to efficiently remove large amounts of trim from several production lines.

In business since 1947, Litin is a converter and wholesale distributor of packaging and industrial supplies. With 32 employees the company operates six converting lines performing cutting, slitting and rewinding in both small and wide diameters. Production includes sheeting, producing packaging paper, counter rolls, butcher, plotter, wax coated, and silicone coated paper, and newsprint.

With so many products diverse in gauge and weight, Litin needed a versatile system, one able to handle the heavy kraft trim as well as the very light, thin-gauge papers and plastics.

According to John Hanson, Litin Vice President/General Manger, handling trim waste, while in itself not a major problem, was a nagging annoyance made worse by Litin’s rapid growth rate.

The Fox Runner™ uses CAC’s widely employed Fox TrimAway® pneumatic trim removal components mounted to a portable stand for permanent, semi permanent and temporary applications.

According to John Hanson, the Fox Runner™ was easy to install and delivered the versatility, energy efficiency, and low maintenance that Litin required.

”It is stable enough to put in place for long term trim handling or it can be easily wheeled to multiple locations throughout the plant and rapidly set up and put to work wherever it is needed,“ Hanson said.

”And finally,“ he added, ”It works great. And it’s quiet! We especially appreciate that.“

Efficient Trim Removal Improves Sustainability

The unique design and performance of Converter Accessory Corporation’s (CAC®) FOX TrimAway®, and FOX Runner® trim removal systems can improve efficiency and reduce energy consumption in web converters’ waste management operations.

Improved efficiency and reduced waste and energy consumption improve the overall sustainability of any converting operation and may help improve scores on the influential Wal-Mart sustainability score card for converters and their customers participating in consumer packaging markets.

Fox's features an adjustable venturi and blower system that allows customers to run the narrowest possible trim. In operations where trim is wound, trim widths must be wide enough to be wound in rolls. In the FOX system trim is transported by the blower / venturi to a collection area allowing converters to minimize the excess waste required by trim winding operations.

Additionally, changing from a trim winding-based operation to a FOX system makes an operation more efficient, and thus more sustainable, by eliminating production interruptions needed to change trim or awkward matrix rolls.

CAC’s employment of frugal energy consuming regenerative blowers in the FOX system allows for a major reduction of energy consumption when compared to systems that use energy gobbling compressors. Since these systems are available in four venturi sizes, with blowers of one to 15 horsepower, CAC is able to customize an entire system to precisely match a converter’s requirements by operating continuously at the maximum speed of the web it serves need without resorting to energy wasteful over-sizing.

FOX systems readily integrate with recycling machinery and can be supplied with CAC choppers when needed. FOX facilitates recycling by conveying trim waste without adding contamination, easily cleanly conveying even adhesive materials to a collection point or to recycling machinery.

Jeff Damour, CAC engineering manager, says CAC’s business philosophy has always been based on making web operations more efficient and thus more sustainable while increasing profits.

“In the web converting industry doing what is good for the environment is also good for business,” Damour said.

About FOX TrimAway® Made in the USA, FOX TrimAway® and the FOX Runner® are engineered for efficient trim removal during production or converting of most web materials including, paper, film, foil, board, nonwovens and textiles. They are effective with trim ranging from 1/16“ to 6“ widths and can operate at speeds up to 4000 feet per minute. FOX systems can be supplied with a CAC chopper and can operate as a single installation or as a coherent system consisting of several FOX TrimAway® systems. A complete CAC FOX TrimAway® system includes all required parts and components needed to begin efficient trim removal. In most cases installation takes less than an hour. The versatile FOX Runner® is a portable version of the FOX TrimAway® that can be quickly engaged and disengaged and easily rolled, on built-in wheels, from one production line to another, as needed. All CAC FOX systems are modular constructions sized to customer requirements. All components are engineered to match each customer’s specifications.

New Variable Speed Drive Option

Converter Accessory Corporation now offers a new variable speed drive (VSD) option with all models of their popular, industry proven FOX TrimAway® pneumatic trim removal systems. This new VSD includes built-in soft starting to accelerate the blower motor in a smooth linear fashion.

CAC offers over 30 standard FOX TrimAway® systems. All may be customized to handle the most demanding trim removal application. CAC manufactures centralized, modular and FOX Runner® portable pneumatic trim removal systems.

Popular Fox Runner Portable Trim Removal with High Efficiency Blower Control

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	Serving our customers

Fall Marks the End of a Special Year

Here in Pennsylvania leaves are turning beautiful shades of yellow, orange and red, still early enough in Fall season that lots of green is still in the mix. The air is crisp in the morning and evenings with the smell of blazing wood fires blended with backyard chefs getting in some last-minute burgers on the grill. This marks the start toward the finish line for 2024, which is a special year for CAC. Converter Accessory Corporation was launched by my father, Lawrence Damour, in 1974, 50 years ago. CAC has seen a lot of changes and tremendous challenges in 50 years; the passing of its’ founder, seven or eight recessions (one of them “the great recession”) and one pandemic, to name a few.

I have fond memories of going into the basement at our house in Succasunna, New Jersey to find my father at his drawing board, T-square in one hand, drafting pencil in the other. My father was an engineer and inventor. Starting out, he used out-of-the-box thinking while he designed unique, custom, unwind, rewind and one-of-a-kind web processing systems. Pouring creativity into his engineering and drafting tools to create equipment designs to solve problems unique to converters of paper, film, foil, textile and nonwoven webs. Eventually, my father patented CAC’s air shaft design and the company was born in 1974.

A few years after launching CAC, my father purchased a small office building in Succasunna, New Jersey. His vision; to supply the converting industry with unique web handling equipment. One by one, CAC has added unique products to its’ already highly successful COR-LOK air shaft and chuck core holding system. These products are designed, specifically, to solve web handling issues burdening converters of paper, film, foil, textile and nonwoven webs. Products like patented WrinkleSTOP anti-wrinkle roller, SimpLok shaft holders, all-electric web guide systems and ultrasound automatic, open loop tension controls. CAC no longer manufactures web guide systems or tension controls. However, incredibly successful WrinkleSTOP is the converting industry’s premier anti-wrinkle system and a mainstay of CAC’s web handling product line, today. SimpLok shaft holders continue as CAC’s popular, simple unwind, rewind and roller mounting system.

CAC's Patented WrinkleSTOP No-Bow Anti-Wrinkle Roller

In 1985 CAC broke ground on a brand-new facility in Blairstown, New Jersey to increase production capacity. We added FOX TrimAway division to CAC. FOX TrimAway systems provide pneumatic waste conveying specifically for edge trim, matrix and die cut pieces. Our COR-LOK line of core holders added mechanical chucks as an additional option for core holding in virtually any unwind or rewind application. During this period CAC developed its’ 6200 series and 6400 series pneumatic brakes.

In 1995 CAC left New Jersey and headed to our current facility in Wind Gap, Pennsylvania. Here we continue to manufacture COR-LOK core holding systems, WrinkleSTOP and a full complement of anti-wrinkle systems, FOX TrimAway pneumatic waste conveying systems, pneumatic brakes and clutches and SimpLok shaft holders. Additionally, CAC has added ShaftLok safety chucks, AB350 adjustable bowed roller, air loaded Adjusta-Pull nip type anti-wrinkle system, idler roller systems with and without coatings and patterns, roller assemblies like nip rollers and dancer rollers, along with CAC’s Trim-AX heavy duty chopper and unique roll handling system. All told, CAC has over seventy-five web handling products at your disposal to make your life easier.

We see tremendous potential in upcoming 2025 with our focus primarily on automation and quality. We have automated and continue to automate every facet of our business from engineering and designing with the latest 3D CAD software to CNC machining center production to advanced web-based information delivery to streamlined customer fulfillment systems. Our goal is to save you, our customer, time and resources. Simply put, using CAC’s 50 years of knowhow, and implementing CAC technology into your converting process will increase your bottom line by saving you time and reducing or eliminating waste, especially when it comes to web handling.

Blessed to work with my family, everyday: (from left to right) me, Jeff Damour, my sisters, Pam DiFrancesca and Cecily Archer and my brother, Rick Damour

https://youtu.be/5JUKPBPLoFs

Converting Equipment by CAC (converteraccessory.com )

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Jeff Damour

CAC Buys Advanced New Machinery to Maintain Quality and Meet Increasing Orders

Converter Accessory Corporation (CAC) has upgraded production capabilities with the purchase of a new, advanced computer controlled Clausing/METOSA CNC2080 lathe.

The Clausing/METOSA CNC2080 will be used in production of CAC’s patented WrinkleSTOP® and Multi-Adjust WrinkleSTOP® linear, smooth surface, anti-wrinkle rolls; efficient FOX TrimAway® pneumatic trim, matrix and waste removal systems; the Patented COR-LOK®, light weight air shafts and chucks and the new pinch point free Shaft-LOK™ safety chuck.

Jeffrey Damour, CAC Engineering Manager, said “The Clausing/METOSA CNC2080 lathe delivers the exceptionally precise, beautifully finished products our customers expect of us. Its CNC computer controls and extensive repeat job memory help us accelerate production and keep delivery times short. The versatility of the CNC2080 also allows us to readily produce unique, precisely machined, custom engineered products. Even as we continue to grow, we are committed to making the investments required to supply high quality web handling equipment with short delivery times and unequaled long term support.”

This is the third Clausing lathe CAC has purchased. Two other Clausing lathes have been on line in CAC’s Wind Gap, Pennsylvania headquarters for several years.

The new Clausing/METOSA CNC2080 lathe was purchased through Action Machinery, Bethlehem, PA.

CAC, celebrating 30 years of success, designs, engineers and manufactures mechanical web handling equipment for converters of paper, film, foil, nonwovens and textiles. Engineered solutions include high quality, cost effective equipment including aluminum core cones, air shafts, trim removal, roll handling equipment, advanced technology wrinkle removal systems and more.

For a new CD that gives detailed CAC product information, white papers and extensive resource information valuable to converters, call or email CAC.

For more information contact Pam Damour, Converter Accessory Corporation, 201 Alpha Road, Wind Gap, PA 18091-1279, (800) 433-2413, fax (610) 863-7818. cac@epix.net Web site: www.handleyourweb.com

Clausing Industrial, Inc., 1819 N. Pitcher Street, Kalamazoo, MI 49007, (269) 345-7155. www.clausing-industrial.com

Action Machinery Co., Inc., 2320 Highland Avenue, Bethlehem, PA 18020. (610) 691-6677.www.actionmachinery.com

With Sustainability as a Goal, Small Improvements Can Deliver Big Results

With more than 46 years experience providing converters with innovative solutions engineered to improve efficiency, Converter Accessory Corporation (CAC®) has the practical knowledge to help customers improve their sustainability.

A family owned company, CAC vigilantly protects a proud reputation for quality engineering, innovative design and attentive customer service. Nationwide experience with nearly every type of web converting has given CAC a deep reservoir of knowledge and the ability to anticipate industry trends and customer needs and priorities.

Today, CAC is thoroughly engaged with contributing to the move toward more sustainable converting and more sustainable finished products.

Jeffery Damour, CAC Engineering Manager says “In addition to improving the efficiency in nearly every facet of web converting, we can help customers down-gauge material; run faster and smoother webs; run challenging recycled materials and more efficiently handle edge trim waste. Improved efficiency, reduced waste, and energy consumption is definitively a more sustainable operation.”

For example, CAC offers two outstanding product families that directly improve sustainability and may help converters help their customers improve their scores on the influential Wal-Mart Sustainability scorecard. The “scorecard” is a comprehensive system that rates every aspect of a package’s sustainability including materials, manufacturing techniques and shipping, and allows Wal-Mart to give shelf space preference to higher scoring products.

WrinkleSTOP® Helps Down-Gauging; Reduces Waste.

WrinkleSTOP® Spreader Rolls remove wrinkles with no web distortion, offer edge-to-edge adjustability, from 0% to 100% spread, while the web is in motion, require no special tools for adjustment and have a broad range of applications. WrinkleSTOP® Spreader Rolls improve overall versatility by extending the reach of materials that can be profitably run on most web operations. They are effective with laminating, slitting, printing, coating, textiles, paper, film and nonwoven production.

“WrinkleSTOP® Spreader Rolls accept many materials at any wrap angle, even with extremely short lead-in and lead-out web distances, and really shows off its performance with thin gauge materials but works equally well with all materials and thicknesses,” Damour said.

In independent performance evaluation tests, WrinkleSTOP® Spreader Rolls removed all the wrinkles, all the time, under rigorous conditions and proved to be the best performer in a broad field of subjects. WrinkleSTOP® Spreader Rolls offer both standard and custom sleeves to match most applications and features high-quality motor-grade bearings.

Damour added: “Strategically employed WrinkleSTOP® Spreader Rolls not only support down-gauging and thinner gauges while generating less waste, they also allow an overall increase in line speeds. Sustainable practices do not have to require compromises. They can also be good business practices. Our aim is to improve efficiency and increase sustainability without compromises in quality or profits.”

Energy Efficient Trim Removal Systems

The unique design and performance of CAC's FOX TrimAway®, and FOX Runner® trim removal systems can improve efficiency and reduce energy consumption in in-house waste management operations.

FOX systems feature an adjustable venturi and blower system that allows customers to run the narrowest possible trim. In operations where trim is wound, trim widths must be wide enough to be wound in rolls. In the FOX system trim is transported by the blower / venturi to a collection area allowing converters to minimize the excess waste required by trim winding operations.

Additionally, changing from a trim winding-based operation to a continuously operating FOX system makes an operation more efficient, and thus more sustainable, by eliminating production interruptions needed to change trim rolls or the even more awkward matrix rolls.

CAC's employment of frugal energy consuming regenerative blowers in the FOX system allows for a major reduction of energy consumption when compared to systems that use energy gobbling compressors. Since these systems are available in four venturi sizes, with blowers of one to 15 horsepower, CAC is able to customize an entire system to precisely match a converter's requirements by operating continuously at the maximum speed of the web it serves need without resorting to energy wasteful over-sizing.

CAC offers technology designed to perform at every critical point in a web. From the simplest aluminum core cone to the most sophisticated unwind/rewind solutions CAC products improve efficiency, help increase profits, reduce waste and energy consumption, allow reduction of material costs through down-gauging and, best of all, are readily available, cost effective, easy to install and are fully supported by an expert and dedicated team.

“Major improvements do not always come from a single, expensive, dramatic addition. They are often the result of expert tweaking and the sum of several small enhancements. When we take a close look at the big picture of a web's performance we almost always spot a couple of critical spots where a small improvement will deliver a big result. Constant improvement, that's what sustainability is all about.” Damour concluded.

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	Wrinkle Removal

How to Get the Most From Your Expanding Surfance Anti-Wrinkle Roller

Expanding surface anti-wrinkle rollers, like CAC's WrinkleSTOP®, are an excellent choice for almost any converting process where web wrinkles are an issue. This type of anti-wrinkle roller removes web wrinkles with a surface that lengthens as it rotates under your web. Things to consider to get the most from your expanding surface anti-wrinkle device:

1) Most of the anti-wrinkle action takes place on the roller face. More wrap angle, up to 180 degrees, around the roll face will provide proportionally more anti-wrinkle effect on your web. Less wrap angle means less potential to remove wrinkles.

2) For expanding surface anti-wrinkle rollers to be effective, the web MUST be in traction with the roller face. Most of the time, expanding surface rollers are used as dead shaft idler rollers, being driven by the web itself. Often, expanding surface rollers turn freer than bowed rollers, but do not turn as free at plain dead shaft idler rollers. Adjustments to web tension, increase wrap angle, higher traction material on the roller face, roller face pattern or "roughening", external drive mechanism are all options to consider to ensure the expanding surface roller surface travels synchronous with the web.

Click here to view our CAC WrinkleSTOP Spreader Roller video on YouTube

3) Lead in and lead out distances are not critical to the amount of anti-wrinkle effect on your web. This means these types of anti-wrinkle rollers are an excellent choice in "tight" areas in your machine.

4) Most of these anti-wrinkle rollers, like WrinkleSTOP, are adjustable, making them ideal for all types of webs, even the most delicate. Always keep this adjustment in mind; use this adjustment to increase anti-wrinkle effect on your web when necessary.

Click here to view our CAC WrinkleSTOP Operation Basics video on YouTube

5) Orientation of this type of anti-wrinkle roller is extremely important. The roll must be rotated from its' journal end to ensure the web enters the roller when its' surface is "short" and exit when the surface is "long". Once that point is oriented the journals should be locked from rotating. ALL expanding surface anti-wrinkle rollers must be dead shaft type rollers. Commonly, when expanding surface rollers are not performing properly, it's due to improper orientation of web entry point (where the web first touches the roller face) and web exit point around the roller circumference.

Remember, it's all about performance and return on investment when considering anti-wrinkle rollers for your process. What do wrinkles cost YOU?

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Jeff Damour

Expanding Anti-Wrinkle Roller with Continuous Smooth Rubber Surface

Expanding surface Spreader Roller – Continuous Rubber Sleeve Type

Description:

This type of spreader is manufactured with a rubber sleeve stretched across its face. On each end of the rubber sleeve there are end collars that clamp and hold the sleeve in place. The end collars are mounted on bearings and an adjustable axle. The sleeve is mounted across a series of flexible rubber disks. The rubber sleeve and end caps rotate together.

Theory of operation:

This roller must be incorporated as a dead shaft idler roller, in order to operate properly. The continuous rubber sleeve is pre-loaded across the face of the roller. The end collars are clamped on to each end of the rubber sleeve. The end collars are then canted with an adjustment screw and flange-axle assembly. The canting adjustment is designed so that the collars are facing each other on one side of the roller face and they are away from each other on the opposite (180°) side of the roller. The continuous rubber sleeve stretches from the point where the collars are facing each other, to where the collars are away from each other. The sleeve then contracts for the next 180° of rotation, from where the end collars are facing away from each other to where they are facing toward each other. Bottom line, the rubber sleeve physically stretches from the short side of the rubber sleeve to the long side of the rubber sleeve, then contracts again. The web enters the contracted side of the rubber sleeve and exits on the expanded side. As this roller rotates, the stretching action of the rubber sleeve spreads the web.

Recommended wrap angle for this roller is from 90° to 180°. More wrap (up to 180° maximum) means more spreading. The amount of spreading is directly proportional to the amount of wrap angle. In other words 180° of wrap will provide for 100% of possible spreading, 90° of wrap will provide 50% of possible spreading, 45° of wrap will provide 25% of possible spreading, etc. Lead-in and lead-out distances are not critical in the application of this type of spreading device, because all or most of the web spreading is taking place on the roller face, not in the entry span to the roller.

Click here to view our video on YouTube

Advantages:

This type of spreader is an aggressive wrinkle removal device.
Spreading amount is adjustable from 0% (no spreading) - 100%.
Spread adjustment can be made from each end of the roller, independent of each other, while the machine is running and with standard tools.
This roller is linear across its face, so tension remains evenly distributed across the roller face.
This roller will not distort or tear the center or edges of a web.
It is available with a multitude of different sleeve compounds including abrasion, chemical and heat resistance and release for adhesive applications.
Roller surface is smooth and linear so it will not mark, scratch or deform a web.
This roller is used with all types of webs.

Disadvantages:

Web speeds are a consideration when utilizing this roller. If the web speed causes the sleeve to balloon, as a result of centrifugal force, then the effect on web may be reduced.
The sleeve is stretching and contracting with every revolution, so the continuous rubber sleeve will degrade over time.
Although spreading does occur across the full width of the roller face, most of the spreading occurs toward the ends of the roller face, so the amounts of spreading are not even in measured increments across the face of this roller.

The future of spreader roller technology:

As converting processes run thinning webs faster and wider, more answers to solve wrinkling problems are required. Today’s converter wants to run more types of webs with the highest level of productivity. Converters will be looking for spreader rollers to remove wrinkles, at high speeds, with no web distortion. Continuing advances in spreader roller technology must strive to supply converters with products and service to gain the highest level of productivity.

Join the conversation

Jeff Damour

Bowed Rollers for Web Converting

September 3, 2024

Curved Axis (Bowed) Spreader Roller

Description:

A Curved Axis (Bowed) Roller spreader roller is manufactured exactly as the name states – the center axle of the roller is bowed (not linear). A series of internal ball bearings, supported by the axle, in turn support a rubber sleeve which is continuous across the face. The amount of curve (bow) in the roller face is application dependent and is available in both an adjustable and non-adjustable version.

Theory of operation:

This roller works based on two different spreading principals.

First, as we know, a web will seek to align itself perpendicular to this roller (as long as it is in traction with the roller). This causes the web to spread at any given interval across its width as it tries to maintain the 90° tangent points across the web width.

Second, the rubber sleeve, which spans the roller, is actually narrower on the entry side than the exit side, so as it rotates, the rubber sleeve stretches and the material, laying on top of the rubber surface, stretches with it.

Because this roller normally operates best with minimal wrap angle, the first spreading principal does most of the work. Less surface contact between the web and the rubber sleeve means less stretching principal will effect overall spreading. However, the spreading based on web handling principal is hardly affected by wrap angle.

Recommended wrap angle is usually less than 30°. Many times, when it appears a curved axis (bowed) roller is not operating properly, this is due to wrap angles to great for the application. More important than wrap angle, lead-in and lead-out distances are critical. Typical lead-in (entry span) to the curved axis (bowed) roller should be approximately double the lead-out distance (exit span). Most of the spreading caused by this roller is done in the entry span to this roller, so the longer the entry span is, the more spreading will be realized. The exit span should be kept to a minimum so the web stays spread. The longer the exit span is, the more chance there is for the spreading affect to be lost (or the web may return to its wrinkled or natural state).

Advantages:

This type of spreader roller is an aggressive spreading device.
This spreader roller is used most often for all types of spreading applications. It is accepted for all facets of converting from narrow web to wide web (it is especially used in wide web applications) and slow speed to high speed.
This type of spreader roller is used with all types of webs in all types of converting processes.
It is available with a multitude of different sleeve compounds including abrasion resistance and reinforced (for extremely high speed applications).
This roller is available in both adjustable and non-adjustable versions.
It will spread multiple slit widths evenly, the only spreader roller used for this application.
This roller has a smooth surface, so it will not mark or scratch the surface of the web.

Disadvantages:

This roller is not linear, so it can permanently distort or tear the center of a web because tension is not evenly distributed across the face of this roller as the web travels over it.
Maintenance is involved and normally this roller must be returned to the manufacturer to be maintained.
Because the rubber sleeve is dynamic (it constantly stretches and contracts with each revolution) the rubber sleeve does wear over time.

Curved Axis (Bow) Bar (stationary, does not rotate)

Description:

A Curved Axis (bow) bar spreader bar can be manufactured from steel or aluminum. Many times this spreading device is nothing more than a pipe, curved, using a pipe bender.

Theory of operation:

This spreading device works differently than a curved axis (bowed) roller. The web handling principals that effect web behavior for a curved axis (bowed) roller are not the same as the effects of a curved axis (bow) bar. The web must slip over the face of this bar because it is stationary, it does not rotate. Therefore, the web is not in traction with the bar so the web handling principal that affects the web where a bowed roller is used does not apply here. Instead, the curved axis (bow) bar works based on a tension differential generated by the raised center of the bar. The center, being raised, has the highest tension. The tension decreases toward the bar ends. This tension differential causes wrinkles to be pushed out from the center of the web. The web is attempting to flow through the path of least resistance, which is closest toward the ends of the bar.

Recommended wrap angle for this spreading device can be from 15° to 90°. Most applications require minimal wrap. More wrap angle usually means more potential web distortion.

Advantages:

This spreading device is extremely easy to manufacture. A pipe bender is all that is required.
This spreading device has a smooth surface.
Low maintenance (no moving parts).
This type of spreader will separate slit widths. However, the amount of spreading is completely tension driven. If tension is not accurate and even across the web, slit spacing may not be kept consistent and even.
This type of spreading device is used with woven, non-woven and paper webs.

Disadvantages:

This type of spreader is not linear, so it can permanently distort or tear the web center.
The amount of bow required is application dependent and there is no set formula for generating the amount of bow. Bow amounts are normally determined through trial and error or past experience.
This type of spreader can scratch and mark the web because the face does not rotate with the web flow.
This bar will create drag on the web; tension problems may result down stream of this spreading device.

Expanding surface anti-wrinkle and spreader rollers in the next installment of this newsletter!!! In two weeks - don't miss it!

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Jeff Damour

Grooved Rollers for Wrinkle Removal

Jeffrey Damour

Engineering Manager at Converter Accessory Corporation

May 13, 2024

Description:

Theory of operation:

Quite simply the theory is that the grooves will push wrinkles out of the web, from the center out to each edge, which, unfortunately is not always the case (see advantages and disadvantages, below).

Recommended wrap angle for this type of spreader roller normally ranges between 90° - 180°.

Advantages when applied as an idler roller:

This type of spreader roller will remove air when air entrainment is a problem (this in itself will help to remove or prevent wrinkles).
Depending on the groove design, these rollers can often be manufactured by most machine shops, rubber roller manufacturer or idler roller supplier. Making this type of spreader one of the least expensive, most readily available types of spreader roller.
Simplicity of design, with no special parts, makes this spreader roller extremely easy to maintain.
Because this roller is linear across its face, it will not stretch, distort or tear any portion of the web.
This type of spreader roller is best suited for use with textiles and non-wovens. It has limited application with papers, foils and films.

Disadvantages when applied as an idler roller:

When this spreader is applied as an idler roller (driven at the surface speed of the web), the grooves do not push wrinkles out from the center of the roller face (even though this is most often believed to be the case). When the surface of the grooved roller is driven at the same speed as the surface of the web (such is the case when used as an idler roller) the tangent point, at any given point across the web or roller face, where the web first touches the roller remains in a constant position through the roller rotation. Because the tangent point of the web lying on top of the groove does not vary, the groove has no cross machine direction movement effect on the web. The belief that the grooves have some effect on the web is mostly an optical illusion (like the illusion caused by a rotating barber shop pole). An engineer once told me an excellent analogy of the non-effect of the grooves on the web in this application (I can’t take credit for the analogy); if you place a plow in a field, does the field plow itself by the rotation of the earth? Of course not, and the reason is because the tangent point of the plow in the field remains constant with the earth in its rotation.
This type of roller does not have a smooth surface so it has the potential to mark the web surface.
Some materials may deform across the web face and the groove will actually form in the profile of the web causing wrinkles.

Advantages when used as a “dead bar” or driven slower or faster than the web:

All the advantages as an idler roller plus one more.
When the surface speed of this type of roller is not synchronized with the web speed (standing completely still is included here) then we get a different level of performance with this type of roller. When this is the case, the grooves will push the web outward toward each edge of the roller face. This effect occurs because the tangent point where the web touches the roller face is ever-changing as the web travels around the circumference of the roller. The changing position of this tangent point ensures that the web, at that point, will travel in the direction the groove is facing.

Disadvantages when used as a “dead bar” or driven slower or faster than the web:

Web marking and scratching will occur much more frequently than with spreader rollers that rotate, at the same rate, with the web.
When there is speed differential between the roller face and the web, the web is not in traction with the roller. For this reason the web position can vary across the roller face causing edge guiding and possibly wrinkling problems down-line of this spreader roller.

Grooved Roller – Soft Flexible Rubber

Description:

Theory of operation:

Recommended wrap angle for this type of spreader roller is strictly application dependent and can vary between 30° to 180°

Advantages:

This type of spreader will remove air when air entrainment is a problem. This will help keep the web in traction with this roller improving its’ operation.
Because this roller is linear across its face, it will not stretch distort or tear any portion of the web.
Because of its soft surface, this roller will not mark or scratch the web.
This type of spreader is used with all types of webs.

Disadvantages:

While the lands do flex under the pressure of the tension on the web, they will return to their natural position as the pressure is being relieved. The pressure is relieved as the web exits the roller. As the lands flex back to their natural position, some of the wrinkles the roller removed may return.
This roller does not have a smooth surface, so some webs may deform inside the groove, taking on the profile of the groove.

Nip type anti-wrinkle system in the next installment of this news letter!!

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Jeff Damour

Why Do Webs Wrinkle?

Jeffrey Damour

Engineering Manager at Converter Accessory Corporation
123 articles
April 15, 2024

Definition of the term Spreader Roll

For the purpose of this presentation, spreader rollers are defined as web transport rollers (driven or idle) that cause cross machine direction web movement, as the web is traveling in the machine direction. There are three purposes of cross machine movement; 1) this action will remove wrinkles, 2) this action can separate slit widths, to prevent interleaving, 3) web width can be stretched a predetermined amount.

This presentation will cover each type of Spreader Roll and how they can be utilized in the applications listed above.

Why do webs wrinkle?

To understand why webs wrinkle and why spreader rollers work, it is necessary to understand the most important web handling principal when it comes to wrinkling. This principal states:

A web will seek to align itself perpendicular to a roll, in its entry span to that roll.

The web must be in traction with the roll for this web handling principal to be true and effect the web behavior. In other words, if the material slips over the roll face then it can wander or remain in its current alignment with a roll not perpendicular to it.

The reason webs wrinkle can be summed up in one expression – lateral compressive forces. This presentation will seek to explain why lateral compressive forces occur, how to avoid them and spreader rollers that will remove wrinkles when these lateral compressive forces cannot be avoided.

Causes of Web Wrinkles

In a perfect world, webs would be flat, without gauge band variations. Roll stock would always be wound with the perfect tension from the core through the full roll diameter. Processes would always be run at the perfect tension for each material and operation. All converting processes would be run in humidity-controlled environment, where temperatures never vary. All rollers would be parallel from unwind to rewind and balanced perfectly. There would be no machine vibration. There would be no long, unsupported web lengths. You get the idea.

Unfortunately we do not live and work in a perfect world. One or a combination of any or all of the circumstances listed above will cause wrinkles.

Web characteristics that will cause wrinkles:

Gauge band variations (thickness variations) across web width, cross machine direction (figure 1) will cause wrinkles because tensions will vary across the web width. These tension variations will cause tensile stress in the thicker areas and compression in thinner areas. This compression causes wrinkles.

Tight side/loose side. This condition is caused by the web being longer (linearly), on one side than the other, in the machine direction. If you were to lay flat an extremely long length of material in this condition under no tension, it would actually arc instead of being straight. This condition again creates tensile stress on the tight (short) side and compression on the loose (long) side, causing wrinkles.

Baggy center, tight edges. The web being longer in the center than the two edges, in the machine direction, causes this condition. If you were to lay material with this characteristic, flat, then you would see ripples or bubbles develop in the center while the edges were straight and flat. In a converting process, webs with this material characteristic will wrinkle because most of the tension that is typically evenly distributed across the full width is mostly distributed on the shorter (machine direction) edges than longer (machine direction) center. Tensile stress on the edges will create lateral compression in the center of the web, causing wrinkles.

Baggy edges, tight center. The web being longer on the edges than the center, in the machine direction, causes this condition. If you were to lay material with this characteristic, flat, then you would see ripples or bubbles develop on the edges while the center was straight and flat. In a converting process, webs with this material characteristic will wrinkle because most of the tension that is typically evenly distributed across the full width is mostly distributed on the shorter (machine direction) center than longer (machine direction) edges. Tensile stress in the center will create lateral compression on the edges of the web, causing wrinkles.

Poorly wound roll stock (parent roll) will cause wrinkles for the following reasons:
Tension too high, especially at the outer layers of the roll can cause inner layers to buckle. This is evident by viewing the end of the roll and observing a starring effect. In extreme cases, the core may even be collapsed. This roll characteristic will cause the web to be wrinkled before it enters a converting process.
Tension too low will cause the roll stock to be wound loose. Layers will slip on each other, making tension control ineffective or intermittent. This will cause the material to neck down (under tension) and expand (when tension is low or nonexistent). These compression and decompression forces will create web wrinkles.

Machine characteristics that will cause wrinkles:

Idler roll buckling or deflection will cause wrinkles because the web will actually deflect out of its normal running plane at different intervals across the web width. This out of plane condition will occur wherever the greatest amount of deflection (usually the center) is in the idler roll. When roll deflection occurs, webs will wrinkle because they will compress toward the deflection point.

Air entrainment in webs as they flow over rollers will cause wrinkles. Air entrainment will create slippage between the web and the roll face. If this slippage occurs, then the web is not in traction with the roll. For the web handling principal, that a web will seek to be perpendicular to a roll in the entry span to that roll, to effect web behavior, it must be in traction with the roll. If the web is not in traction with a roll, it can wander or stay aligned with that roll to which it is not perpendicular. Webs that wander will wrinkle because the web will move to be perpendicular to the next roll with which it has traction. This movement to remain perpendicular will cause a strain on the web. Air entrainment problems can be detected by viewing idler rollers that stop rotating during the converting process. Also, if wear spots are seen across idler roll faces, air entrainment is probably the problem. Machinists’ bluing dye can be applied to idler rollers where air entrainment is suspect to detect wear spots.

Material roll buckling or deflection. If the parent roll deflects on its support mechanism (air shaft, mechanical chucks or core cones mounted on a simple steel through shaft) then compressive forces will cause the material roll to buckle and wrinkle before the web enters the converting process.

Varying tension through several different types of processes in one converting line (figure 10) will cause wrinkles. A good example of this is tension through a coating section, printing process, drying section and slitting section. Tension through the coating section may be high, then through the printing process may be lower, then through the drying process lower yet, then through the slitting section may be high again. Wrinkles will occur under these conditions because the web will stretch and contract creating compressive and decompressive forces.

Lateral (cross machine direction) compressive forces are created in the web because of a high tension. Decompressive forces are created from the web trying to return to its natural state after leaving a high-tension section. These lateral compressive and decompressive forces are very similar to stretching and relaxing a rubber band. When you stretch a rubber band, its length grows and its width narrows (lateral compressive forces make the rubber band narrow). When the same rubber band is relaxed, the length shortens and the width grows as it tries to return to its natural state (lateral decompressive forces). These individual tension sections (zones) can be affected by braked, defective or unbalanced idler or driven rollers that will create tension variations as the web is flowing through the process.

A braked roller, defective roller or a defective bearing in an idler roller, will cause tension to vary on the downstream side of the idler roll. This will vary tension very similar to the situation described above. Again, as tensions vary, the web will stretch and contract creating wrinkles.

Other web expansion and contraction effects on the web will create wrinkles. Examples of these effects are heat on plastics and moisture in paper.
If idler rollers and/or driven rollers are not parallel to each other, wrinkles will occur. These occurrences are again introduced because of the web handling principal, that a web will seek to align itself perpendicular to a roll in the entry span to that roll. As the web is seeking this right angle it will move or bend out of its normal running plane. This will create tension to variations across the web, tensile stress in high tension area and lateral compression in the low tension area.

Why use spreader rollers?

To remove wrinkles. As described in the previous section, webs will wrinkle for a lot of reasons. Some times, wrinkles can be avoided by correcting certain errors in converting processes. Many times, wrinkles will reoccur even though it seems all conditions are perfect in the converting process. These reoccurring wrinkles can only be removed with a spreader roll.

Spreader rollers used to remove wrinkles will do so prior to the wrinkle becoming a crease. If a wrinkle becomes a crease it becomes very difficult or usually impossible to remove. A wrinkle will become a crease when it enters a station where the web is being nipped or rewound.

Typically, spreader rollers are used as a “bandage” for wrinkling problems. Spreader rollers do not permanently change the characteristics of material. Multiple spreader rollers may be required for one converting process, each roll located just prior to each converting operation where wrinkles cause a problem or may become creases.

Applications where accumulated wrinkles require more cross machine movement than one spreader roll can provide will require multiple spreader rollers. Usually, multiple spreader roll applications will incorporate several of the same type of spreader rollers, each immediately following the other, again just prior to each operation where wrinkle removal is required. Different types of spreaders should not be used in close proximity to each other, because each type utilizes different principals of web spreading. Many times, when different types of spreaders are used together, results can become unstable and unpredictable. Some times, different types of spreaders will counter act each other and cause wrinkles, this usually does more harm than good.

Imagine the print quality out of a printing station or edge quality out of a slitting station with an in-running wrinkle or crease. Spreader rollers are used to improve product quality and reduce waste by removing some, most or all of the wrinkles just prior to a converting operation. Bottom line – spreader rollers used to remove wrinkles will increase profits by reducing or eliminating defective product. With the use of spreader rollers, web speeds can often increase and webs that could not be run without wrinkling (example-very thin or soft webs) in the past can now be processed with little or no problems.

To separate slit widths, to prevent interleaving. When a web is slit into several separate widths, each width takes on the properties of a separate web. Each width will have its own tension and each width will have a tendency to wander, similar to how the parent web can wander (this is why the parent web is usually edge guided).

Normally, several slit widths are wound on a duplex (two station winder). This type of rewind has two separate rewind shafts, each with its own drive. Use of a duplex rewind will prevent interleaving by placing each slit width alternately, on the two separate rewind shafts. Example – The first slit width is placed and rewound on to shaft A, the second slit width is placed and rewound on shaft B, the third slit width is placed and rewound on shaft A, etc. Because each slit width is placed with the space of the next slit width between each rewound roll it is impossible for interleaving to occur.

However, in applications where several slit widths are wound on to a single rewind shaft, edge interleaving will occur with even the slightest wander by each slit width. When this interleaving occurs with several layers of web wraps on the rewind shaft, the edges of each slit roll will become overlapped. It is very difficult or impossible to separate each rewound roll if the edges are overlapped.

Bowed (curved axis) spreader rollers will prevent edge interleaving and roll overlap on a single rewind shaft by evenly separating each slit width. The separation must be greater than the maximum cumulative web wander for each slit width. This separation principal works, based on the web handling principal that the centerline of each slit width (now having the properties of a separate web) will seek to be perpendicular to the intersection point on the arc (curved axis) of the bowed roll.

To stretch the web across the width. Some applications require that a web be stretched in the cross machine direction. A good example of this is a tenter frame application, often used for textiles. While a tenter frame is not a spreader roll by definition it does stretch material in the cross machine direction. Spreader rollers are used quite often immediately following a tenter frame to keep the web taught, so it doesn’t return to it’s natural width state. Spreader rollers may be used in this application to increase stretch in the cross machine direction.

All spreader rollers have the ability (with varying aggressiveness) to stretch a web. Each uses it’s inherent spreading principal to do so which we describe further in the document (see Principals of Operation for each type of spreader).

We will discuss crowned and concave rollers in the next installment of this news letter.

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How Closed Loop Tension Controls Work

Tension measurement control

There are two types of tension measurement tension controls – dancer roll and load cell types. These controls are “closed loop”. They control tension based on tension in the web. They will compensate for tension changes due to roll diameter change on an unwind and rewind. They will also compensate for tension changes due to splices, bearings, mechanical losses and any of forces acting on the web in the machine direction.

Because these tension controls are “closed loop” and control drives based on actual web tension, they can be used to control the unwind, internal and rewind tension zones. Unfortunately, these controls can not sense roll diameter without external inputs, so by themselves they can not supply taper tension to rewind zone applications.

Tension measurement control - dancer

There are many different designs of dancer roll tension controls. However, all dancers operate with a common principle. They all incorporate idler rolls that are “loaded” in one direction, while the web tends to move them in the opposite direction. A sensor detects the position of the dancer and tells the drive to increase or decrease in speed or torque to add or remove material from the dancer. As long as the dancer roll remains between its physical limits (completely empty or completely full) tension is constant on the web.

Some of the most common types of dancer roll designs are pivot arm, linear and rotational. One advantage to using dancer roll tension controls that is consistent among all designs is they all have some amount (some designs more than others) of web storage. In other words, dancers actually accumulate a certain length of web in the machine direction. That means they can be designed to be mechanically stable through large roll build ratios (at the unwind and rewind) and will absorb tension fluctuations due to splices, defective bearings or other factors. Dancers not only control torque and/or speed to keep tension constant, they also absorb tension fluctuations, so web tension down stream of the dancer is kept smooth.

Pivot arm type dancer roll tension controls advantages:

This design of dancer is one of the simplest.
Most common design of dancer roll tension control.
Least expensive dancer design.
Can be designed with a large or small amount of web storage, but takes up a lot of space.

Pivot arm type dancer roll tension control disadvantages:

Gravity must be taken into account during design.
Unit can be bulky and difficult to fit into an existing process.
Momentum and inertia is a concern.

Linear type dancer roll tension controls advantages:

This design is compact.
Large amounts of web storage are available. Especially with multiple web passes. Excellent design for accumulation needs, to allow splices on the fly.
Small package can be easy to install in existing equipment.

Linear type dancer roll tension control disadvantages:

Gravity must be taken into account during design.
Can be a very complex design.
One of the most expensive designs. Rodless cylinders and linear transducers are very expensive.
Momentum and inertia is a concern.
Rodless cylinders are not available in a low friction model.

Rotational type dancer roll tension controls advantages:

This type of dancer roll design is not effected by gravity. It’s dancer rollers are counterbalanced with each other.
Momentum and inertia is greatly decreased with the “push/pull” motion.
Generous web storage in a small package.

Rotational type dancer roll tension controls advantages:

This design can be expensive.
This dancer roll design is somewhat complex.
Web storage amount is fixed and determined by design. Increasing web storage is a new design.

Friction, gravity, momentum and inertia are all “enemies” of dancer rolls. These factors must be accounted for when designing dancer roll tension controls.

Frictional losses greatly affect the accuracy of dancer roll tension controls. Low friction cylinders, such as glass lined or rolling diaphragm cylinders, should be used. Stay away from standard o-ring type cylinders or any type of cylinder with a high breakaway force.
Momentum and inertia affect stability and accuracy of dancers. Remember a body in motion wants to stay in motion, so dancers will want to keep moving in the direction they are headed. This could cause the dancer to be unstable and tension spikes. Design dancers as lightweight as possible and avoid weight loading of dancers this will greatly reduce momentum and inertia problems.
Gravity affects dancer accuracy. The weight of the dancer must be overcome by the web tension order for the dancer to operate. This weight of the dancer is in addition to the loading on the dancer when considering total web tension delivered to the web. Design dancers so gravity least affects them. Rotational type dancers are not prone to gravity problems because the dancer rollers counterbalance each other. Instead of designing a pivoting or linear dancer to move perpendicular to the floor, design it to move parallel to the floor. This will greatly reduce gravity problems.

There are many methods of loading dancer roll tension controls. Older units may be loaded with weights. If you need more or less tension you add or subtract weight. Newer dancer roll tension controls may use air cylinders for loading with pressure regulator valves. If you want more or less tension your turn the valve to allow more or less air pressure into an air cylinder. Today dancers are manufactured with electric to pneumatic converters loading low friction cylinders, such as glass lined or rolling diaphragm types. Electric to pneumatic converters are electronic circuits, which receive a signal voltage and output a proportional air pressure. The actual air pressure output is sensed with a pressure transducer and controlled with an electronic pressure regulator. This closed loop sensing circuit allows for very accurate dancer roll loading.

Older dancer position sensors are normally potentiometers. The problem associated with using a potentiometer to sense dancer position is that you have mechanical parts within the potentiometer (wiper against a resistance coil) that constantly wear against each other. This type of sensor may loose accuracy over time and may need periodic replacement. Newer dancer position sensors can be digital potentiometers, encoders or proximity sensors with analog output. These types of sensors do not have mechanically wearing parts, so their accuracy is not affected over time and the need for replacement is rare.

Tension measurement control – load cell

Load cell tension controls utilize strain gauges and other weight measuring devices to measure the “weight” applied to an idler roll due to tension. The force exerted to the idler roll due to tension in the material is proportional to wrap angle around the roll. The example below shows 180° wrap. However, load cell tension controls work with any amount of wrap angle up to 180°. Wrap angles around the idler rolls utilizing load cells must not vary through roll diameter, that is why these controls use lead-in and lead-out idler rolls.

The machine operator sets the desired tension. Normally measurement signals are generated on both sides of the idler roll and fed into the control unit. The control accepts both signals and processes them together. Process values and set values are compared and an output is generated and sent to the drive to keep tension constant.

Load cell tension controls advantages:

Excellent, accurate tension control at the unwind, rewind and internal zones.
Many makes and models to choose from.
Very accepted though out the industry for tension control.
“High tech” controls are available with IO for PLC interface and data acquisition.
Auto-tune units are available to eliminate manual calibration.
Inexpensive, simple units are available.
Very easy to install at any idler roll location.
Minimal machine modifications are necessary to utilize this control.

Load cell tension control disadvantages:

No mechanical web storage for web tension fluctuations.
Web tension can be unstable. Especially in unwind and rewind zone control with large roll build ratios

It can be difficult to properly design both dancer roll and load cell tension controls to have 100% “authority” over an unwind or rewind drive. Large roll build ratios, very high and low speeds and elastic webs can make both types of closed loop controls very unstable. Combination open loop / closed loop controls are available to help with this problem.

Open loop controls are very stable because they are designed to measure distance (roll build). Unfortunately, open loop controls lack accuracy because they do not know what the tension actually is in the web.

Closed loop controls are very accurate because they actually measure tension in the web and control a drive to keep tension constant relative to a set point. Unfortunately, closed loop control can lack stability when controlling unwind and rewind tension zones because they do not know distance (roll build) and have to control large ratios in a relative small span.

Combination controls utilize both open loop and closed loop technology for unwind and rewind zones. The open loop control in the system normally controls 90% of the output to the drive and the closed loop control “trims” that output 10%. This makes unwind and rewind zone control very stable and very accurate. Theses controls utilize roll diameter information, so taper tension for rewind applications is available.

Combination closed loop / open loop tension control advantages:

Very accurate, very stable tension control for very demanding applications.
“High-tech” controls are available with IO and PLC interface.

Combination closed loop / open loop tension control disadvantages:

High cost of two tension controls.
Mechanically and electronically complex.

When tension controls are applied properly, they will decrease waste due to web defects. They will allow operators to concentrate their efforts in other critical areas of your process. Tension controls can allow you to run your process faster. They can even allow you to run different webs and processes through your machine. Tension controls are essential to increasing your profits.

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Written By: Jeff Damour

How Open Loop Tension Controls Work

How do open loop tension controls work?

First, a word about the term drive.

In many of the descriptions throughout this presentation I refer to the term “drive”. I am using this term as a purely generic term to describe a mechanical device that delivers torque to a roll of material or driven roll(s) in a converting machine. This device could be a motor, brake or clutch. This presentation is not meant to detail drive mechanisms; instead its intent is to describe the fundamental mechanics of tension control systems.

Manual tension control.

The simplest and least expensive method of tension control is manual. They can be as simple as a potentiometer adjusting the torque output of a drive or magnetic particle brake or clutch or an air regulator adjusting the air pressure and therefore torque output of an air brake or clutch. This control method can be used in all three tension zones. Obviously, it is the least accurate of all types of tension controls because it relies completely on operator “feel” to set the proper tension. There is no feedback from the machine to verify any actual process tension levels. Often times they will have some sort of “meter” on the front of the control to display output as a reference point.

Unwind and rewind tension zones are the most difficult to control manually because of constantly changing diameters and therefore need to be constantly adjusted.

Diameter measurement control.

There are several types of diameter measurement controls. Each type has its own method of sensing the unwind and rewind roll diameter. These controls are extremely useful for controlling the tension off an unwind and onto a rewind. However, because they control tension by proportionally decreasing (unwind) or increasing (rewind) torque relative to roll diameter change, they do not work for internal tension zones. These types of tension controls are used strictly at the unwind and rewind tension zones. These controls can be supplied with taper tension for rewind zone applications.

Diameter measurement control – follower arm.

Follower arm or lay-on roll type control is the oldest technology for diameter measurement. This type of control has a wheel or roll, which lays on the unwind or rewind roll outer diameter. The wheel or roll is mounted to a pivoting arm. The pivoting arm is spring or air loaded with a sensing device mounted to the pivot point. The sensing device is usually a potentiometer, but proximity sensors and hall-effect sensors are also common. This sensing device feeds back to the tension control and an output is generated to the drive to control torque proportional to roll build.

Follower arm tension control advantages:

This type of tension control is very simple.
Good replacement for operator controlled manual control.
Inexpensive.
Easy to install.

Follower arm tension control disadvantages:

Normally, this control does not have compensation for out of round rolls. Out of round rolls could cause this control to oscillate.
The lay-on roll or wheel gets in the way of changing rolls.
Major mechanical modifications are necessary to increase unwind or rewind roll capacity.
There are a lot of mechanical parts, which will require maintenance.
This is an open loop tension control. It does not control tension by measuring tension in the web. It controls tension by measuring roll diameter. It assumes all of the conditions effecting web tension are correct.
This type of tension control can only control unwind and rewind zones. It cannot control internal zones.
Material must be contacted, which could harm some sensitive materials.

Diameter measurement control – ultrasound:

Many advantages over the follower arm type tension control make the ultrasound tension control a more popular choice today. The ultrasonic sensor emits a signal that travels to the rolls surface, bounces off and returns to the sensor. The control logic measures the time it takes for the signal to return to the sensor and in that way measures distance. Since the control measures distance, it will give a linear output relative to the radius of the roll to a drive device. As we discussed earlier, the equation torque = tension x radius is linear, so if the ultrasound tension control gives a linear output relative to radius it will control drive torque through an unwind or rewind roll built to supply constant tension.

Ultrasound tension control advantages:

This type of tension control is very simple.
Excellent replacement for operator controlled manual control.
Relatively inexpensive.
Extremely easy to install.
Gives a true linear output relative to roll diameter.
Models of this control are available with compensation for out of round rolls to eliminate control oscilation.
Ultrasonic sensor can be “tucked” away, out of machine operators way. It can be mounted anywhere around the roll circumference, as long as it get a clear view of roll radius.
Modifications to increase unwind or rewind roll capacity is easy. All that is needed is to move the transducer and recalibration.
No mechanical parts to wear out.
Models are available with limit alarms. Such as low or empty roll.
No material contact for sensitive materials.

Ultrasound tension control disadvantages:

This is an open loop tension control. It does not control tension by measuring tension in the web. It controls tension by measuring roll diameter. It assumes all of the conditions effecting web tension are correct.
This type of tension control can only control unwind and rewind zones. It cannot control internal zones.
Any object put between the roll outer diameter and the transducer affects it.
Electronic calibration is necessary with initial set up.
Some types of material, such as nonwovens, may absorb the ultrasonic signal. If the signal does not return to the sensor, it will not operate.
The perpendicular positioning of the sensor relative to rolls centerline is somewhat critical. If the sensor is “knocked” out of position, it may not operate properly.

Diameter measurement control – diameter calculator

The last type of diameter measurement control we will discuss is the diameter calculator. This type of control uses sensors at the unwind or rewind shaft and an idler or driven roll. Both sensors detect RPM. They can be encoders or tachometer generators.

Machine speed is constant and known. Unwind and rewind roll speeds both vary relative to roll diameter. By comparing the constant known speed to the varying unwind or rewind roll speed, diameter can be calculated.

Diameter calculator tension control advantages:

Excellent replacement for operator controlled manual control.
Relatively inexpensive.
Relatively easy to install.
Gives a true linear output relative to roll diameter.
Nothing in the way of roll loading or unloading
Modifications to increase unwind or rewind roll capacity is easy. All that is needed is recalibration.
No mechanical parts to wear out.
Models are available with limit alarms. Such as low or empty roll.
No material contact for sensitive materials.

Diameter calculator tension control disadvantages:

This is an open loop tension control.
It does not control tension by measuring tension in the web. It controls tension by measuring roll diameter. It assumes all of the conditions effecting web tension are correct.
This type of tension control can only control unwind and rewind zones. It cannot control internal zones.
Control logic is somewhat complex (compared to ultrasonic or follower arm type). 9 Electronic calibration is necessary with initial set up.

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Written By: Jeff Damour

How do I measure tension in my existing process?

Most converting applications include three types of tension zones – unwind, internal and rewind. Each zone must be controlled independently. Multiple zones of each type are common in many converting applications; however, they normally are categorized as unwind, internal or rewind.

Each tension zone is very unique and must be controlled independently. Since independent tension controls are used in each zone, each zone may have its own tension level. This means, for example, tension in the unwind zone may be 1 PLI then increase to 2 PLI in the internal zone then decrease to 1.5 PLI in the rewind zone.

Torque required to provide a certain level of tension to a web is total tension measured across the web times roll radius. This means the torque driving the unwind shaft must decrease at a linear ratio, relative to roll diameter, as an unwind roll decreases in size, through a machine run, to keep tension constant. Conversely, the torque driving the rewind shaft must increase at a linear ratio, relative to roll diameter, as a rewind roll increases in size, through a machine run, to keep tension constant. Tension in the unwind and rewind zones is very dynamic. Roll diameters are constantly changing, so torque and speed must be constantly adjusted relative to changing roll diameters. Tension and speed in the internal zones is much more stable since roll diameters in these zones does not change. However, some control is required to set and maintain desired levels. Web defects, splices, desired machine speeds, machine defects and other variables will effect tension in the internal zones.

Remember the equation of torque = tension x radius is linear, so torque must be decreased (for unwinds) and increased (for rewinds) at a linear rate relative to roll radius. For example, if you start with a 17.5 inch roll radius (35 inch diameter) and unwind down to a 1.75 inch core radius (3.5 inch diameter); 17.5 divided by 1.75 is 10:1 ratio. That means, if you start at 100 inch pounds of torque at the beginning of the unwind roll for proper tension, the torque must be linearly decreased to 10 inch pounds of torque at the core to maintain constant tension.

The machine designer must determine required tension levels for each zone. Often times required tension levels can only be determined after actually running the web through the machine, since all webs and all processes are somewhat unique. TAPPI (Technical association of the Pulp and Paper Industry), as well as many other industry organizations, publish estimated proper tension levels for several different types of webs and laminations. However, keep in mind these values are only guidelines and “best estimates” based on many years of combined industry experience. The actual best tension to run your specific web and process will, most likely, vary from the guideline. Another very general rule of thumb is proper web tension is usually between 10-25% of the tensile strength of your web.

You can measure the tension at which you currently run your process. There are several methods for doing this.

If you already have a load cell tension control, it normally has the ability to display actual tension in total pounds across the web. You can also purchase load cells with only a display (no control) if you would like to measure tension within any zone in your machine.

If your machine has dancers, you can calculate the loading of the dancer on the web if you know the web geometry and the loading force on the dancer. To do this, you will need a drawing of the dancer and web path through the dancer. You also need to know the type of loading and the force applied. Another simpler method would be to place a scale of some sort to measure the force the dancer is loading on the web. Do this without web threaded through the dancer. Remember, as long as the dancer remains somewhere within its travel (between its physical limits of completely full or completely empty) the tension on the web is equal to the loading in the dancer.

Another crude but very effective way to measure tension in the unwind zone is the “fish scale method”. This method works for the unwind zone only. It can only be utilized if there is a brake on the unwind station. Unwrap a small amount of material off the unwind roll. Set the unwind brake to the torque output normally set for a machine run. Wrap the leading edge of the web around a bar and hook the “fish scale” through the bar. Pull on the fish scale until the unwind starts to turn. Record the weight reading on the fish scale. This is the actual tension on the web, at this point. Divide the total weight by web width in inches to get PLI (Pounds Per Linear Inch). Do not attempt this method of measuring tension if there is a drive motor on the unwind or for a rewind with a drive motor. Serious injury could result if this method of measuring tension is attempted when there is a drive motor at the unwind or rewind zone.

Tension can also be calculated if you know the model of a brake or clutch, the output level to that brake or clutch at a given roll diameter. By knowing the torque output of the brake or clutch we can plug the values into torque = roll radius x tension and extrapolate the actual tension the brake or clutch is delivering to the web.

Taper tension:

Everything we have discussed so far is based on constant tension applications. Do not confuse constant tension by varying (or tapering) torque to achieve constant tension as taper tension. Taper tension is NEVER desired for the unwind or internal zones. As a web is unwound and is processed, constant web tension is ALWAYS desired. Taper tension is normally desired in the rewind zone.

As a roll is rewound each layer builds up compressive forces which can cause inner layers, toward the core, to buckle. Wrinkling, starring and crushed cores will occur if these compressive forces become to great. Taper tension relieves these compressive forces by actually decreasing web tension as the roll builds. The amount of taper tension is normally measured in percentage of set tension. For example, using the same 3.5 inch core diameter and 35 inch outside roll diameter, if taper tension was set to 50%, the tension will be linearly decreased from 3.5 inch core to 35 inch roll diameter so the tension will be half at the outside of the roll compared to the core.

We will discuss how tension controls work in the next installment.

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Written By: Jeff Damour

How do we select the most effective wrinkle removal solutions?

Jeffrey Damour

Engineering Manager at Converter Accessory Corporation
108 articles
September 5, 2023

Most anti-wrinkle rollers remove wrinkles. Concave rollers, grooved rollers, nip type spreader rollers, bowed rollers and expanding surface rollers all remove wrinkles. They may vary in their aggressiveness and the amount of wrinkles they take out, but they all work to some extent to help with web wrinkle problems.

So how do you select the right one? Well, the question to ask yourself (and your supplier) is what are the rollers doing to my material in the long run? Especially with new directives handed down from your customers to run thinner materials.

Thinner materials wrinkle more because they are less stable than their thicker counter parts, so when you attempt to convert thinner gauge "stuff" you may get wrinkles where you never had them before. Be careful how you select your next anti-wrinkle roll to help solve this problem.

Anti-wrinkle rollers can harm and distort your thin materials (paper, film, foils, non-wovens). Bowed rollers and concave rollers have non-linear faces, which will increase the tension profile of the web in certain areas and decrease it in other areas. This may stretch or distort your webs permanently. Grooved rollers and nip type spreaders have non smooth surfaces which may mark your web or cause different wrinkles.

So while these rollers do remove wrinkles, sometimes the most important question is - What am I doing to my materials by using these rollers? Often times these types of spreaders can cause more harm than good.

Try to find an anti-wrinkle roller with linear face and smooth surface. They aggressively remove wrinkles with zero web distortion and deformation.

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Written By: Jeff Damour

New On Shaft Inflation Toggle Valve Air Shaft Makes Roll Changes More Efficient

CAC hosts an online air shaft support center featured on www.converteraccessory.com offering detailed instruction for servicing air shafts from CAC and other manufacturers. The air shaft support center allows for online ordering of spare parts, including aluminum core cones, tubing, valves and valve cores.

In addition to detailed instruction, online chat is also available, but not required to access information. Currently celebrating its 49th year of success, Converter Accessory Corporation designs, engineers and manufactures web handling equipment for converters of paper, film, foil, nonwovens and textiles. Engineered solutions include high quality, cost effective equipment from the simplest aluminum core cone to the most sophisticated unwind/rewind system. CAC® is represented by knowledgeable sales engineers and provides extensive consultation and post sales support.

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Written By: Jeff Damour

What is Web Tension and Why Do I Care?

What is tension?

Typically, tension is measured in PLI (Pounds per Linear Inch) in the US. If you know PLI and you want to know total tension applied to the web, multiply PLI times the width of the material in inches. If you know total pounds of tension applied to the web and you want to know PLI, divide the total pounds of tension across the web by the width of the web in inches.

• PLI (Pounds per Linear Inch) = total pounds of tension / web width in inches

• Total pounds of tension = PLI X web width in inches

The tension applied to a web can be described as the webs tautness as if you hung a weight off the edge of the web. The tension on the web would be equal to the weight in pounds. PLI would be equal to the weight in pounds divided by the web width in inches.

Why is tension important to me?

• It is impossible to control your web without proper tension being applied. The web must be “in traction” with all machine idler rolls and driven rolls to ensure proper web handling and control.

• The web handling principal states a web will seek to align itself perpendicular to an idler or driven roll. This web handling principal is applied to route webs through processes with parallel idler rolls and driven rolls. It is applied when web guides are used to steer webs. And it is also applied in many wrinkle removal devices. However, the web handling principal does not apply to webs that are not in traction with idler or driven rolls. In other words if the web slips over the face of an idler or driven roll it can wander from side to side or if the web slips on web guiding idler rolls it will not move where the web guide attempts to steer it. Tension must be applied to webs to keep them in traction with idler and driven rolls.

• All webs stretch in the machine direction as tension is applied to them. It is important to apply proper tension to a web so that it can be handled through the machine and processes without over-stretching

• It is impossible to unwind rolls into a process without proper tension control at the unwind station. Telescoping, “dished” rolls, wrinkles and even web breaks will occur when tension is not controlled at the unwind station.

• It is impossible to rewind rolls from a process without proper tension control at the rewind station. Telescoping, “dished” rolls, wrinkles and even web breaks will occur when tension is not controlled at the rewind station.

• Many converting operations require proper registration to print or die cut stations. Proper tension control is essential to controlling print to print or die cut registration.

• Laminating operations require layers to be laminated with proper tensions to avoid web curl.

• Slitting operations require proper slit position, which is a function of tension and web guiding.

• When tension is too high webs will stretch in the machine direction and compress in the cross machine direction. This narrowing of the web width can cause wrinkles to occur.

• When tension is too low webs will shrink in the machine direction and web width will widen in the cross machine direction. This widening of the web width can cause wrinkles to occur.

Understanding what web tension is, its function in your converting process and why it is important are the first steps to properly controlling web tension to benefit your operation.

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Written By: Jeff Damour

Nip Type Anti-Wrinkle System for Web Converting

Description:

Nip type spreader rollers are normally short face rollers (less than 12” face) and small diameter (less than 3” diameter). These rollers are supplied in a left and right hand set. Each set consists of 2 rollers pre-loaded so each roller face is pressed together; these roller faces must be parallel with each other. Each roller set is very similar in design to other nip rollers used in converting (such as drive nips). One of the rollers in each set must be rubber covered (for traction); sometimes both rollers in the set are rubber covered.

Theory of operation:

The left and right-side nip sets are mounted to the machine frame and each edge of the web is fed through the nip rollers. The left and right side nip roller sets are then angled away from each other, facing in the downstream direction. Because of the web handling principle, that a web will seek to align itself perpendicular to a roller, in its entry span to that roller, each web edge will seek to be perpendicular to each nip roller set. This type of spreader roller is extremely aggressive and will spread more aggressively than most other types of spreader rollers.

This type of spreader roller has no wrap angle. Because the web is not supported across its full width, the material must be fed straight in and out of this spreader roller assembly.

Advantages:

This type of spreader roller is the most aggressive.
Simplicity of design makes this type of spreader roller easy to maintain.
The amount of spreading is easily adjustable, by changing the angle of each nip set independently of each other.
Works well with woven and non-woven webs.

Disadvantages:

Because this spreader roller will not support the web across its full width, it will mark, distort and possibly tear most foils.
This type of spreader roller is specifically designed for woven and non-woven materials. Any other type of materials may have difficulty with this type of spreader roller, because of web distortion.

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Written By: Jeff Damour

Why Do Webs Wrinkle?

Definition of the term Spreader Roll

This presentation will cover each type of Spreader Roll and how they can be utilized in the applications listed above.

Why do webs wrinkle?

To understand why webs wrinkle and why spreader rollers work, it is necessary to understand the most important web handling principal when it comes to wrinkling. This principal states:

A web will seek to align itself perpendicular to a roll, in its entry span to that roll.

Causes of Web Wrinkles

Unfortunately we do not live and work in a perfect world. One or a combination of any or all of the circumstances listed above will cause wrinkles.

Web characteristics that will cause wrinkles:

Gauge band variations (thickness variations) across web width, cross machine direction (figure 1) will cause wrinkles because tensions will vary across the web width. These tension variations will cause tensile stress in the thicker areas and compression in thinner areas. This compression causes wrinkles.

Tight side/loose side. This condition is caused by the web being longer (linearly), on one side than the other, in the machine direction. If you were to lay flat an extremely long length of material in this condition under no tension, it would actually arc instead of being straight. This condition again creates tensile stress on the tight (short) side and compression on the loose (long) side, causing wrinkles.

Baggy center, tight edges. The web being longer in the center than the two edges, in the machine direction, causes this condition. If you were to lay material with this characteristic, flat, then you would see ripples or bubbles develop in the center while the edges were straight and flat. In a converting process, webs with this material characteristic will wrinkle because most of the tension that is typically evenly distributed across the full width is mostly distributed on the shorter (machine direction) edges than longer (machine direction) center. Tensile stress on the edges will create lateral compression in the center of the web, causing wrinkles.

Baggy edges, tight center. The web being longer on the edges than the center, in the machine direction, causes this condition. If you were to lay material with this characteristic, flat, then you would see ripples or bubbles develop on the edges while the center was straight and flat. In a converting process, webs with this material characteristic will wrinkle because most of the tension that is typically evenly distributed across the full width is mostly distributed on the shorter (machine direction) center than longer (machine direction) edges. Tensile stress in the center will create lateral compression on the edges of the web, causing wrinkles.

Poorly wound roll stock (parent roll) will cause wrinkles for the following reasons:
Tension too high, especially at the outer layers of the roll can cause inner layers to buckle. This is evident by viewing the end of the roll and observing a starring effect. In extreme cases, the core may even be collapsed. This roll characteristic will cause the web to be wrinkled before it enters a converting process.
Tension too low will cause the roll stock to be wound loose. Layers will slip on each other, making tension control ineffective or intermittent. This will cause the material to neck down (under tension) and expand (when tension is low or nonexistent). These compression and decompression forces will create web wrinkles.

Machine characteristics that will cause wrinkles:

Idler roll buckling or deflection will cause wrinkles because the web will actually deflect out of its normal running plane at different intervals across the web width. This out of plane condition will occur wherever the greatest amount of deflection (usually the center) is in the idler roll. When roll deflection occurs, webs will wrinkle because they will compress toward the deflection point.

Air entrainment in webs as they flow over rollers will cause wrinkles. Air entrainment will create slippage between the web and the roll face. If this slippage occurs, then the web is not in traction with the roll. For the web handling principal, that a web will seek to be perpendicular to a roll in the entry span to that roll, to effect web behavior, it must be in traction with the roll. If the web is not in traction with a roll, it can wander or stay aligned with that roll to which it is not perpendicular. Webs that wander will wrinkle because the web will move to be perpendicular to the next roll with which it has traction. This movement to remain perpendicular will cause a strain on the web. Air entrainment problems can be detected by viewing idler rollers that stop rotating during the converting process. Also, if wear spots are seen across idler roll faces, air entrainment is probably the problem. Machinists’ bluing dye can be applied to idler rollers where air entrainment is suspect to detect wear spots.

Material roll buckling or deflection. If the parent roll deflects on its support mechanism (air shaft, mechanical chucks or core cones mounted on a simple steel through shaft) then compressive forces will cause the material roll to buckle and wrinkle before the web enters the converting process.

Varying tension through several different types of processes in one converting line (figure 10) will cause wrinkles. A good example of this is tension through a coating section, printing process, drying section and slitting section. Tension through the coating section may be high, then through the printing process may be lower, then through the drying process lower yet, then through the slitting section may be high again. Wrinkles will occur under these conditions because the web will stretch and contract creating compressive and decompressive forces.

Other web expansion and contraction effects on the web will create wrinkles. Examples of these effects are heat on plastics and moisture in paper.
If idler rollers and/or driven rollers are not parallel to each other, wrinkles will occur. These occurrences are again introduced because of the web handling principal, that a web will seek to align itself perpendicular to a roll in the entry span to that roll. As the web is seeking this right angle it will move or bend out of its normal running plane. This will create tension to variations across the web, tensile stress in high tension area and lateral compression in the low tension area.

Why use spreader rollers?

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Written By: Jeff Damour

How Open Loop Tension Controls Work

Published on January 3, 2023

How do open loop tension controls work?

First, a word about the term drive.

Manual tension control.

Unwind and rewind tension zones are the most difficult to control manually because of constantly changing diameters and therefore need to be constantly adjusted.

Diameter measurement control.

Diameter measurement control – follower arm.

Follower arm tension control advantages:

This type of tension control is very simple.
Good replacement for operator controlled manual control.
Inexpensive.
Easy to install.

Follower arm tension control disadvantages:

Normally, this control does not have compensation for out of round rolls. Out of round rolls could cause this control to oscillate.
The lay-on roll or wheel gets in the way of changing rolls.
Major mechanical modifications are necessary to increase unwind or rewind roll capacity.
There are a lot of mechanical parts, which will require maintenance.
This is an open loop tension control. It does not control tension by measuring tension in the web. It controls tension by measuring roll diameter. It assumes all of the conditions effecting web tension are correct.
This type of tension control can only control unwind and rewind zones. It cannot control internal zones.
Material must be contacted, which could harm some sensitive materials.

Diameter measurement control – ultrasound:

Ultrasound tension control advantages:

This type of tension control is very simple.
Excellent replacement for operator controlled manual control.
Relatively inexpensive.
Extremely easy to install.
Gives a true linear output relative to roll diameter.
Models of this control are available with compensation for out of round rolls to eliminate control oscilation.
Ultrasonic sensor can be “tucked” away, out of machine operators way. It can be mounted anywhere around the roll circumference, as long as it get a clear view of roll radius.
Modifications to increase unwind or rewind roll capacity is easy. All that is needed is to move the transducer and recalibration.
No mechanical parts to wear out.
Models are available with limit alarms. Such as low or empty roll.
No material contact for sensitive materials.

Ultrasound tension control disadvantages:

This is an open loop tension control. It does not control tension by measuring tension in the web. It controls tension by measuring roll diameter. It assumes all of the conditions effecting web tension are correct.
This type of tension control can only control unwind and rewind zones. It cannot control internal zones.
Any object put between the roll outer diameter and the transducer affects it.
Electronic calibration is necessary with initial set up.
Some types of material, such as nonwovens, may absorb the ultrasonic signal. If the signal does not return to the sensor, it will not operate.
The perpendicular positioning of the sensor relative to rolls centerline is somewhat critical. If the sensor is “knocked” out of position, it may not operate properly.

Diameter measurement control – diameter calculator

Diameter calculator tension control advantages:

Excellent replacement for operator controlled manual control.
Relatively inexpensive.

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Written By: Jeff Damour

COMMON ANTI-WRINKLE SYSTEMS

Nip Type (each edge of the web) Spreader Roller System

Description:

Theory of operation:

The left and right side nip sets are mounted to the machine frame and each edge of the web is fed through the nip rollers. The left and right side nip roller sets are then angled away from each other, facing in the down stream direction. Because of the web handling principle, that a web will seek to align itself perpendicular to a roller, in its entry span to that roller, each web edge will seek to be perpendicular to each nip roller set. This type of spreader roller is extremely aggressive and will remove more web wrinkles, more aggressively than any other type of anti-wrinkle system.

This type of spreader roller has no wrap angle. Because the web is not supported across its full width, the material must be fed straight in and out of this spreader roller assembly.

Main advantages:

● This type of anti-wrinkle system is the most aggressive.

● Simplicity of design makes this type of spreader roller easy to maintain.

● The amount of spreading is easily adjustable, by changing the angle of each nip set independently of each other.

Main disadvantage:

● Because this anti-wrinkle system does not support the web across its full width, it may mark or distort foils. Typically, this anti-wrinkle system is not used with foil webs.

Bowed rollers

Description:

A bowed roller is manufactured exactly as the name states – the center axle of the roller is bowed (not linear). A series of internal ball bearings, supported by the axle, in turn support a rubber sleeve which is continuous across the bowed roller face. The amount of curve (bow) in the roller face is application dependent and is available in both an adjustable and non-adjustable versions.

Theory of operation:

This roller works based on two different web spreading principles.

Second, the rubber sleeve, which spans the roller face, is narrower on the entry side of the roller than the exit side, so as it rotates, the rubber sleeve stretches and the material, laying on top of the rubber surface, stretches with the rubber sleeve.

Recommended wrap angle is usually less than 30°. Many times, when it appears a bowed roller is not operating properly, this is due to wrap angles to great for the application. More important than wrap angle, lead-in and lead-out distances are critical. Typical lead-in (entry span) to the curved axis (bowed) roller should be approximately double the lead-out distance (exit span). As you can see in the illustration, most of the spreading caused by this roller is done in the entry span to this roller, so the longer the entry span is, the more web wrinkles will be eliminated. The exit span should be kept short so the web stays spread. The longer the exit span is, the more chance there is for the spreading affect to be lost (or the web may return to its wrinkled or natural state).

Main advantages:

● This type of spreader roller is an aggressive anti-wrinkle device.

● Bowed rollers are very common. They are accepted for all facets of converting from narrow web to wide web (it is especially used in wide web applications) and slow speed to high speed.

● This type of spreader roller is used with all types of webs in all types of converting processes.

● This roller has a smooth surface, so it will not mark or scratch the surface of the web.

Main disadvantages:

● Bowed rollers are not linear, so they can permanently distort the center of some webs. Because web tension is not evenly distributed across the face of bowed rollers, added tension delivered to the center of the web (due to curved shape of the bowed roller) may cause this distortion.

● When maintenance is required this roller is normally returned to the bowed roller manufacturer.

● Because the rubber sleeve is dynamic (it constantly stretches and contracts with each revolution) the rubber sleeve does wear over time.

Expanding Surface Anti-Wrinkle Roller

Description:

This type of anti-wrinkle roller is manufactured with a rubber sleeve stretched across its face. On each end of the rubber sleeve there are end collars that clamp and hold the sleeve in place. The end collars are mounted on bearings and an adjustable axle. The sleeve is mounted across a series of flexible rubber disks. The rubber sleeve and end caps rotate together.

Theory of operation:

Recommended wrap angle for this roller is from 90° to 180°. More wrap (up to 180° maximum) means more wrinkle removal. The amount of web spreading is directly proportional to the amount of wrap angle. In other words 180° of wrap will provide for 100% of possible spreading, 90° of wrap will provide 50% of possible spreading, 45° of wrap will provide 25% of possible spreading, etc. Lead-in and lead-out distances are not critical in the application of this type of anti-wrinkle device, because all or most of the web spreading is taking place on the roller face, not in the entry span to the roller.

Main advantages:

● This type of anti-wrinkle system is an aggressive wrinkle eliminating device.

● Anti-wrinkle aggression is adjustable from 0% (no spreading) - 100%. Adjustment can be made while the web is running with standard tools. Each side of the roller is independentally adjustable.

● This roller is linear across its face, so tension remains evenly distributed across the roller face. So, this roller will not distort your web.

● Roller surface is smooth and linear so it will not mark, scratch or deform a web.

● This roller is used with all types of webs.

Main disadvantages:

● Web speeds are a consideration when utilizing this roller. If the web speed causes the sleeve to balloon, as a result of centrifugal force, then the roller may not operate properly.

● The sleeve is stretching and contracting with every revolution, so the continuous rubber sleeve will degrade over time.

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Written By: Jeff Damour

FOX Runner™ Portable Pneumatic Waste Removal System

Ready to run in 15 minutes, roll in place and hook up power!

CAC portable systems are shipped completely assembled and ready to use. As with all FOX TrimAway systems, FOX Runner has a unique venturi at its heart. Teamed with a powerful, efficient and quiet regenerative blower, FOX Runner is able to generate suction and pressure air streams to pick up and convey your edge trim, die cut pieces or matrix from your machine.

Turn Key for fast and easy installation and operation
Portable for operation at different stations
Systems available to discharge over 100 feet
Energy efficient
Systems available to handle up to two 6 inch wide trims, up to 6,000 FPM
Click here for additional information!

Efficiently remove paper, film, foil, textile and non-woven trims. Great for picking up and removing pieces (die cutter) as well as chopped, granulated and palletized materials.

Click here to see our products

Web Spreading System Employs Simple Principle for Effective, Economical Results

Converter Accessory Corporation's (CAC) new Adjusta-Pull® web spreading system is a remarkably efficient and cost effective approach to wrinkle removal and web spreading. Adjusta-Pull is an aggressive system, especially effective with nearly all textiles and nonwovens as well as paper and film applications.

According to Pam Damour, CAC General Manager, the entirely mechanical system employs the web principle that a web will seek a 90° angle to a roll in its entry span to that roll.

Adjusta-Pull® consists of two opposing nip roll assemblies that use this principle to impose a consistent, controlled outward draw on the web material. Easily adjusted angular displacement, relative to the direction of the web flow, influences the amount of draw and thus allows regulation of the amount of spreading action.

Ball bearing mounted Adjusta-Pull® nip rolls in nine and six inches come in standard one rubber/ one aluminum configurations, but may be supplied with virtually any covering, including plasma, silicone, urethane, Teflon, etc., for spreading materials with special requirements.

For additional web spreading, Adjusta-Pull® can be arranged in sequences of multiple pairs.

Damour said: ”This is a reliable web spreading system that is easy to install, requires little maintenance, consumes no energy and delivers an exceptionally fast return on investment. We have so much confidence in this system that we offer trial installations to qualified customers.“

In addition to Adjusta-Pull®, CAC has several other types of wrinkle removal systems, including the widely successful WrinkleSTOP®. CAC's product diversity allows customers to select optimal wrinkle removal technology for each application.

For more information contact Pam Damour, Converter Accessory Corporation, 201 Alpha Road, Wind Gap, PA 18091-1279, (800) 433 2413, fax (610) 863 7818. cac@epix.net Web site: www.handleyourweb.com

Industry Leading Converter to test WrinkleSTOP® 3000

Converter Accessory Corporation (CAC) has produced a WrinkleSTOP® 3000 for beta installation in a fortune 500 company. The new WrinkleSTOP® 3000 anti-wrinkle rolls are engineered to be compatible with web production speeds up to 3000 feet per minute, doubling the speed capabilities of previous versions. WrinkleSTOP® 3000 anti-wrinkle rolls are available in 8 inch diameters and widths up to 200 inches. The 8 inch diameter, 72 inch face beta version is custom engineered to match the customer's requirements.

More than 2000 previous versions of WrinkleSTOP® are successfully in use in North America. In addition to improving quality and significantly reducing scrap, in some cases to zero, WrinkleSTOP® anti-wrinkle rolls have consistently allowed an overall increase in line speeds.

According to Jeff Damour, Engineering Manager, WrinkleSTOP® anti-wrinkle rolls remove wrinkles with no web distortion, offer edge-to-edge adjustability, from 0% to 100% spread, while the web is in motion, require no special tools for adjustment and have a broad range of applications. WrinkleSTOP® anti-wrinkle rolls improve overall versatility by extending the reach of materials that can be profitably run on most web operations. WrinkleSTOP® anti-wrinkle rolls are effective with laminating, slitting, printing, coating, textiles, paper, film and nonwovens production.

In a recent independent performance evaluation test, WrinkleSTOP® anti-wrinkle rolls removed all the wrinkles, all the time, under rigorous conditions and proved to be the best performer in a broad field of subjects. All WrinkleSTOP® anti-wrinkle rolls offer both standard and custom sleeves to match most applications and feature high-quality motor-grade bearings.

”Most converters are always interested in technology that will allow them to go thinner, faster and wider. Our newest WrinkleSTOP® anti-wrinkle rolls were developed to match these demands for top performance at high speeds in wider webs. WrinkleSTOP®, in all configurations, remains the best wrinkle removing upgrade for web processing under all conditions, including the widest range of materials at any wrap angle, even those with extremely short lead-in and lead-out web distances,“ Damour said.

Currently celebrating its 32nd year of success, Converter Accessory Corporation designs, engineers and manufactures web handling equipment for converters of paper, film, foil, nonwovens and textiles. Engineered solutions include high quality, cost effective equipment from the simplest aluminum core cone to the most sophisticated unwind/rewind system. CAC is represented by knowledgeable sales engineers and provides extensive consultation and post sales support.

For more information contact Jeff Damour, Converter Accessory Corporation, 201 Alpha Road, Wind Gap, PA 18091-1279, (800) 433 2413, fax (610) 863 7818, or click above to chat with an on-line sales engineer.

Written By: Jeff Damour, Sales Manager, Converter Accessory Corporation, Wind Gap, PA
Phone - 800-433-2413

Spreader Rolls Support Improved Sustainability of Web Produced Products

WrinkleSTOP® Spreader Rolls can help converters and their customers offer more sustainable products. WrinkleSTOP® has a proven ability to improve the quality of web production, reduce waste and effectively run thinner gauge materials.

With material costs skyrocketing and new demands for “greener” products converters are facing new challenges to their ability to compete profitably. Since the Wal-Mart sustainability scorecard went into effect in February, sustainability pressure on converters participating in the packaging markets has significantly increased. The “scorecard” is a comprehensive system that rates every aspect of a package's sustainability including materials, manufacturing techniques and shipping, and allows Wal-Mart to give shelf space preference to higher scoring products.

Jeff Damour, CAC Engineering Manager, said: “Strategically employed WrinkleSTOP® Spreader Rolls not only support down-gauging and thinner gauges while generating less waste, they also allow an overall increase in line speeds. Sustainable practices do not have to require compromises. They can also be good business practices. Our aim is to improve efficiency and increase sustainability without compromises in quality or profits.”

About WrinkleSTOP®

“WrinkleSTOP® Spreader Rolls accept many materials at any wrap angle, even with extremely short lead-in and lead-out web distances. It really shows off its' performance with thin gauge materials,” Damour said. “However, it works equally well with all materials and thickness”

Thin webs without wrinkles

Any converter running webs of thin- and ultra-thin gauge material, including foil, may experience wrinkle problems. In general, there are at least two excellent solutions to wrinkle problems, but only one-expanding surface spreader rolls-is the preferred choice for converters running thin gauges. Expanding surface spreader rolls have proven to provide the best wrinkle removal for virtually any application in web widths 3-120 in. They are effective in any printing, coating, or laminating operation, and their performance is especially noteworthy when applied to thin-gauge film and foil.

Studying the Systems

An impartial examination and evaluation of the performance of all wrinkle-removing systems came in a definitive study published in a bound edition, edited by J.K. Good, of the Fourth Intl. Conference of Web Handling, held June 1-4, 1997, at the Web Handling Research Center, Oklahoma State Univ., Stillwater, OK. The specific study, “Testing and Analysis of Web Spreading and Anti-Wrinkle Devices” by R.P. Swanson, 3M Co., (pp414-428), found “the expanding surface rollers did not wrinkle under any test conditions. The regime I performance was excellent. This roller is an aggressive web-spreading device. An expanding surface roller would be insensitive to wrinkles at low, medium, and high tensions. This roller is an excellent, high drag, web spreading and anti wrinkle device.” (p421). Of the ten types of systems tested, only the expanding surface spreader rolls and the “curved axis” or bowed roll systems were described as “excellent” systems according to the study.

The single distinguishing drawback of bowed spreader rolls, compared to expanding surface spreader rolls, is the potential web-distorting effect built into the design (See Figures 1 and 2). The arc itself, the core of the design principle, has the potential of stretching and even tearing the center of the web. With many materials, depending on the amount of distortion, this may not be an issue. But with very thin gauges, as is often the case with foils and films, the capacity to absorb any distortion of materials is limited. Tears and stretching may result, and the impaired quality may be more noticeable than it might be with other materials.

Figure 1

Figure 2

When compared to bowed spreader rolls, the only other system to receive an “excellent” in the Swanson study, the expanding surface spreader roll is distinguished by its ability to maintain a constant tension profile while acting on the web.

Example Makes the Point

Let’s take a look at a typical expanding surface spreader roll. This example (same example as the Swanson study) employs a stretchable rubber sleeve supported by a series of rubber support disks. On each end of the sleeve, there are end collars mounted on bearings and an adjustable axle. The end collars clamp and hold the sleeve in place. Importantly, however, the end collars are canted to a mechanically adjustable degree, and it is this cant that provides the contracted and expanded pattern of the stretching section of the roll. (See Figures 3 and 4).

Figure 3

Figure 4

Essentially and simply, during production the web continually stretches from the short side of the rubber sleeve to the long side. The material enters the roll at the point where sleeve expansion begins and exits at a point prior to sleeve contraction. The desired spreading action is achieved without distortion of the web.

Wrinkle removal comes from the expanding action evenly distributed across the web. The amount of expansion may be adjusted at each end of the web – continually, if necessary – to compensate for distortions derived from changing up-stream conditions.

This type of spreader is an aggressive wrinkle-removal device. Spreading amount is adjustable from- 0%-100%. Adjustments can be made from each end of the roll while the machine is running. The recommended wrap angle for this roll is from 90°-180°, the greater the wrap angle, the greater the stretch.

For converters of thin-gauge materials, or where consistent gauge and unmarred surfaces are especially important, the expanding surface spreader roll maintains an even tension across the surface and does not distort or tear the center or edges of a web. Also, the smooth surface does not mar, scratch, or distort web surfaces.

Benefits Outweigh Flaws

With a couple of minor caveats (the system does not distribute the stretch across the web perfectly, and its effectiveness may be inhibited at extremely fast web speeds), the expanding surface spreader roll has proven to be the most effective wrinkle-removal system available for thin-gauge materials.

It is true almost every spreader roll will remove some level of wrinkles, and a converter’s selection of a system should be guided, in part, by the degree of wrinkle removal desired and, in part, by the amount of distortion converters and their customers can tolerate. While both bowed roll and expanding surface spreader rolls offer an excellent performance, when it comes to thin- and ultra-thin gauge materials and when quality is paramount, the expanding surface spreader roll is the preferred choice.

Jeff Damour is the engineering manager at Converter Accessory Corporation, Wind Gap, PA. He has been with CAC for 17 years and has published several technical articles covering a wide range of web handling applications. Jeff has the honor of presenting web spreading technology for converters at the Slitting and Rewinding Fundamentals and Coating and Laminating seminars run by Converting Equipment Mfrs. Assn. (CEMA). Contact Jeff at 800-433-2413; jdamour@converteraccessory.com. The views and opinions expressed in Technical Reports are those of the author(s), not those of the editors of PFFC. Please address comments to author(s).

CAC Adds Adjustable Mounting Bracket to Adjusta-Pull® Anti-Wrinkle System

Converter Accessory Corporation’s (CAC) NEW adjustable mounting bracket is the perfect value added option for use with CAC’s Adjusta-Pull® anti-wrinkle system.

According to Jeff Damour, CAC Engineering Manager, this new mounting bracket includes a cantilevered extruded aluminum slide rail frame allowing easy web width adjustment. The hand operated angle adjustment knob makes for easy side to side tuning of anti-wrinkle action.

Four bolt mounting makes these mounting brackets extremely easy to mount. They may be purchased to accompany any new Adjusta-Pull applications or added to existing Adjusta-Pull nip type anti-wrinkle systems in the field. Simple, one bolt mounting of the Adjusta-Pull® system to the bracket is all that is required.

Damour said: "We have designed these mounting brackets with ease of installation and versatility of use in mind. I highly recommend this mounting system for any Adjusta-Pull® anti-wrinkle application, new or already existing."

Adjusta-Pull® nip type anti-wrinkle systems employ two opposing nip roll assemblies that are mounted to each edge of the web. The nip assemblies are angled away from each other. Each web edge will attempt to maintain a 90 degree entry angle to each Adjusta-Pull® nip assembly effectively pulling on each edge of your web, removing wrinkles. The system is a very simple answer to the very complex and expensive problem of web wrinkles.

CAC Expands Anti-Wrinkle Product Line with Introduction of Bowed Roll

Converter Accessory Corporation (CAC) is introducing bowed rolls to its’ already extensive line of anti-wrinkle technology and devices. The new model FB350 bowed roll utilizes fixed bow technology, engineered to fit customers’ specific application(s). Fixed bow provides excellent aggressive, repeatable performance for the most demanding anti-wrinkle applications. It is also extremely well suited to separate slit widths for slitter rewinder applications, to prevent interleaving.

The FB350 is currently available in versatile 3.5” diameter and face widths up to 70”. Drive sheaves are available for light tension applications. Rubber sleeve material may be varied where high heat, chemicals, adhesives or excessive ozone exposure may be a concern. Optional mounting blocks, designed for use with the FB350, allow for optimal bow placement in any application.

According to Jeff Damour, CAC engineering manager, the inclusion of bowed rolls to an extensive anti-wrinkle product offering greatly enhances CAC’s ability to offer complete standard and customized solutions to eliminate web wrinkles in any converting process. The new FB350 bowed roll will join WrinkleSTOP, Multi-Adjust WrinkleSTOP, Adjusta-Pull, Angular Adjusta-Pull bracket, Scroll Roll and crowned and concave rollers to accommodate a truly complete and unique array of solutions to combat web wrinkles.

FB350 bowed rolls are acceptable for use with textiles, all types of plastic films, paper and non-wovens. They can be used in applications from slow speed to high speed, narrow web to wide web. More information can be found at FB350 3.50 diameter Bowed Roll

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Trim Removal System

Serving our customers

WrinkleSTOP® Helps Down-Gauging; Reduces Waste.

Energy Efficient Trim Removal Systems

Wrinkle Removal

Where Web Tension Exists, How to Measure Tension and a Word About Taper Tension

Definition of the term Spreader Roll

Ready to run in 15 minutes, roll in place and hook up power!

Studying the Systems

Example Makes the Point

Benefits Outweigh Flaws