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
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.
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.
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).
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; firstname.lastname@example.org. 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).
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.”
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. It really shows off its' performance with thin gauge materials,” Damour said. “However, it works equally well with all materials and thickness”
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.
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.
Phone - 800-433-2413
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.
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 Damour, Converter Accessory Corporation, 201 Alpha Road, Wind Gap, PA 18091-1279, (800) 433 2413, fax (610) 863 7818. email@example.com Web site: www.handleyourweb.com
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