As automation continues to trend as one of the hottest label manufacturing topics, Martin Automatic has emphasized its latest advancements to simplify the converting process. Martin Automatic specializes in automating the press to continue running non-stop, while also providing operators with some of the best ergonomic advantages in machine operation.

For example, Martin Automatic has focused on automatic roll unloading of the rewind. This feature allows the operator freedom to continue press tasks without having to be present during the roll transfer – or even the sequence of unloading the roll from the rewind spindle.

“The goal of automation is always to give operators more freedom to perform higher value-added tasks while increasing productivity and saving resources,” explains Gavin Rittmeyer, vice president of sales and marketing, Martin Automatic. “With the ongoing shortage of labor and material, and increasing costs of material and other inputs, saving time and material continues to gain importance. Converters continue to look more closely at roll automation and ergonomics to give their operators greater freedom and flexibility, which in turn allows operators to advance their trade to produce the highest quality labels at the lowest possible cost.”

Martin Automatic’s automatic advances are numerous. They include interface with vision systems that allow tagging the finished, full width roll, or even the individual slit rolls, any print defects. Especially for slit rolls, this capability leads to greater productivity, as only those slit rolls that might have a defect need to be edited. With inline roll slitting automation, converters can also choose to print wider web widths – slitting, for example, a wider web into two narrow webs that can then be fed into off-line slitter-rewinders.

Direct view sheer slitting modules and removal anvil shafts for off-line setup of anvils improve setup time and comfort for operators changing jobs and slitting patterns, adds Rittmeyer. Horns conveniently located next to the slitter module are easy to reach and allow stripped waste to be easily set up and sucked away. Customized web paths from the press to the rewind allow operators easier access to slitter stations, improving ergonomics of machine setup. Martin Automatic has also designed an easy-to-access core port door to allow off-line setup of cores, with tape and guides operators conveniently to correct core placement on the waiting, automatically prepositioned, empty spindle.

Plus, the creative use of HMI screens coordinate the most important production and operation information in “easy-to-get-at” screens that are bright, color-coordinated and not filled with “setup” details, information and heavy text. And moving repeat operations to a few specific machine-mounted pushbuttons reduces stress from having to search for these routine buttons on HMI screens, the company notes.

“Press operators have many complex responsibilities to produce today’s high-tech labels,” says Rittmeyer. “Martin strives to make operation of its rewinds as simple and easy as possible. Our most popular rewinds for the label industry – the STR, LRD and LRH rewinds – feature cantilevered spindles which remain with the machines at all times; operators do not have to manipulate, or remove ‘loose’ core shafts from finished rolls.

“Easy to use, easy to understand, and easy to maintain equipment will always improve press uptime and employee satisfaction,” adds Rittmeyer. “Our focus on operator convenience, intuitive HMI displays and pushbutton use and placement continue to improve operator interaction with the process and create flexibility that allows operators to spend more time on the press.”

Inspection is also a key part of the converting process, and these capabilities have improved significantly over the year, as well. According to Rittmeyer, when winding full width rolls or slit rolls in line, interfacing with inspection systems is possible. This integration allows the inspection system to tag the rewound rolls to identify if there might be defects. For full width rolls that are converted further, this tag communicates to the editing process and allows for faster turn-around of the edited roll. For rolls that are slit and rewound in inline, this tagging allows the converter to bypass any further offline processing for rolls that wind with no or “the accepted minimum defect rate” – only those slit rolls that exceed the defect threshold need to be edited.

“The advantages to minimizing further inspection off-line and/or skipping the off-line editing process altogether are obvious: labor saving in handling rolls needlessly, less work in progress (WIP); fewer rolls feeding to off-line inspection and doctoring system; less floor space for editing equipment or WIP to name a few,” he comments.