The issues associated with dirty webs are plenty. Converters seeking the utmost quality for their labels should take a deep dive into web cleaning.

There are a host of considerations for label converters investigating this vital converting segment. All web cleaners must have a number of requirements for successful cleaning: Effective static elimination of the web and contamination; Breaking the boundary layer of air on the web surface; Disturbing and removing the surface contamination; and successfully isolating and trapping all of the disturbed contamination.

As Matt Fyffe, VP and general manager, Meech USA, states, contact and non-contact cleaners work on different principles. “For contact cleaner, tacky roll systems are probably the most common size of web cleaning in the market,” explains Fyffe. “These are contact cleaners and are good for narrow, slow moving webs of film. They do not perform well on paper or coated stocks as the amount of debris collected will require frequent replacement of the adhesive which is a consumable.”

Meanwhile, vacuum-based systems are designed specifically for paper and board. They use a faceplate that touches the surface of the web and pump or blower that then adds suction to the web to remove the debris. Additionally, rotary brush cleaners will have a rotating brush combined with positive and negative airflows. The rotating brush will contact the web and scrub off the debris. The airflows will then lift off the debris and convey it to a collection system.

“Non-contact cleaners use high-velocity, positive air flows to clean off the web with a turbulent air flow,” says Fyffe. “Negative pressure is then used to extract the removed contaminants, which are then conveyed away and stored in a collection system. Non-contact systems are also ideal for use with low tension applications or in tight fitting areas of the press. They are typically the best solution for retrofitting on existing machinery.”

There are a multitude of factors to be considered when determining what type of web cleaner a converter should use. “The type of material should be the first thing to be addressed,” notes Fyffe. “For example, paperstocks are typically much ‘dirtier’ than films, which means that they will require a cleaning system that is better suited for high contaminant levels. We should then also consider if the material is sensitive or prone to marking. This will then help us to determine if we can use a less expensive contact cleaner or need to upgrade to a non-contact system.”

Following those two factors, there are few other items to consider. “Do we need single- or double-sided cleaning, what is the web tension, speed of the web, what is the maximum size of the contaminant that needs to be removed?” adds Fyffe.     

What is the downside to ignoring this technology? Print can be adversely affected. “Every year printers and converters are held to a higher and higher standard,” remarks Fyffe. “Contaminants on the web can result in a multitude of problems, including poor print quality, high reject rates in the printing, laminating, or coating process, excessive downtime on printing presses, frequent blanket washing, unacceptable quality in pharmaceutical or food packaging, and the costly rework of refused orders. The installation of a properly specified web cleaning system will alleviate any of these issues.”

From a product standpoint, Meech offers web cleaning solutions for all types of cleaners. For contact web cleaning, the company provides the TakClean, VacClean, and RoClean systems.    For non-contact, it offers the CyClean for standard double-sided cleaning and the CyClean-R for low tension applications.   

“It is best to talk to a web cleaning specialist that has experience of the different methods of web cleaning, as there is no such thing as a one-fits-all web cleaner. There are advantages and disadvantages of each. A proper specialist will be able to ask the right questions to drill down on the best fit for each application,” concludes Fyffe.