In the narrow web industry, the slitter rewinder is a crucial part of the label converting process. After printing on a large roll of labelstock, this machinery consolidates the labels into multiple narrower rolls. A roll of material is transported from an inline rewinder to an offline slitter rewinder. The roll is then unwound and slit into narrower webs. These webs are subsequently rewound as individual ribbons, which are narrower than the parent roll.

As in other aspects of converting, slitting rewinding has seen an increase in automation due to electronic enhancements. The industry is currently seeing wider widths and faster speeds. According to Tom Giles, senior account manager, Aztech Converting Systems, manufacturers in this field need to foster relationships with partners on the digital printing front. “Significant strides made over the last several years in the offerings and quality of digital printing equipment have revitalized the need for quality re-registering converting and finishing systems,” he says. “Although the digital printing companies don’t generally like to be in the position of recommending specific finishing equipment systems to their clients, they are interested to suggest familiar companies based on client need and budget.”

The current machinery also offers more flexibility and can handle a wider array of substrates. According to Jim Ward, vice president of operations at Kocher+Beck, it is important to educate customers and operators, so they know what the machines can support. “It’s really more about getting educated on what’s required to run these different materials, but our machines are designed to handle a wider range,” he says. “These machines are flexible out of the gate, and since we have a software update, as we find things we can do better down the road – a different winding curve or tension profile – they can be added to any machine around the world easily.”

There are various ways that rolls can be slit and rewound, and equipment manufacturers take a different approach to the process. The following is an account of what some of the leading suppliers offer.

AB Graphic International
AB Graphic is a leader in fully modular digital converting, inspection rewinding equipment and turret rewinding. The company also produces machinery for RFID insertion, laser diecutting, booklet label machines and 100% camera inspection systems.

AB Graphic offers the SRI (inspection slitter rewinder) in its Omega Inspection Slitter/Rewinder range. The SRI utilizes the newest servo driven technology combined with PC/SPS based controls. The equipment operates with a rewinding speed of 350 mpm with maximum web widths of 330mm, 430mm or 530mm. The SRI was originally launched at Labelexpo 2013 and has had 130 installations worldwide. The company has been in this market for over 20 years and has sold thousands of units over that time period.

“The SRI was specifically designed for high-speed slitter inspection applications and includes a 100% print face inspection camera imbedded into the control,” explains Tony Bell, sales director, AB Graphic. “As both the camera and rewinder are manufactured in the same plant, that is unique to us. It offers seamless integration of the FleyeVision system, which is particularly noticeable on setup and waste removal.”

The Autoslit system with label gap sensor sets the slitting knives on the slitter rewinder. The operator presses a button, and a scanner passes across the web identifying where the gaps are and automatically positions the slitting blades. This is designed to save hours of make-ready times each week on short run jobs. “Our customers are demanding a wider range of substrates to include unsupported film,” adds Bell. “In response, we have developed new features to accommodate this, as well as more detailed camera inspection systems.”

In addition to its slitter rewinders, AB Graphic offers a full product line of print finishing solutions. The range includes the Digicon Series 3, a modular digital finishing solution, the Digicon-Lite 3, a compact and economic finishing machine, the full servo Converter Series 3, the Vectra range of automatic turret rewinders and other camera inspection systems.

“We don’t stand still – we are constantly innovating and improving,” says Bell. “We also offer JDF compatibility for our SRIs and think we’ll see more take up of this option from customers as streamlining of the workflow becomes more important.

“The whole industry is becoming more competitive so we need to focus on efficiencies and fast setup for our customers,” adds Bell. “Modern rewinders are a long way from the old equipment that used to be acceptable back then. With the market changing and run lengths becoming shorter as more converters move into digital finishing, we see this as a challenge to the number of slitter rewinders being sold in the future. Obviously though, it’s not a challenge for us as we have a comprehensive range of digital finishing equipment.”     
www.abgint.com

AZTECH Converting Systems
Aztech Converting Systems, a provider of converting systems, accessories and materials handling equipment, was established in 1984. Based in Tempe, AZ, USA, the company offers two models of inspection slitting and rewinding equipment.

The BSR (Base Slitter Rewind) features a small footprint and 40″ diameter unwind rolls and up to 24″ diameter rewound rolls, all while operating at a 750 fpm line speed. Web widths range from 10-20″ and customers can choose from a single or dual spindle rewind. Aztech also provides a strobe inspection station as an available option.

The ISR (Inspection Slitter Rewinder) features a larger footprint with dual splice tables and dual inspection areas. Like the BSR, web widths range from 10-20″, while 30″ diameter unwind rolls and up to 18″ diameter rewound rolls are available. As standard, the BSR system is equipped with a strobe inspection station, and is a platform adaptable for adding 100% vision inspection capability.

“We provide robust, affordable and dependable equipment,” says Giles. “Mechanically, our systems are easy to understand and operate. Because we concentrate on what we know best and make use of standard designs, we don’t require the degree of engineering staffing that our competitors employ.”

In addition, the company offers the DM and DMRR DieMaster rotary diecutting and finishing systems. That product line comes standard with large diameter 40″ unwind, automatic web steering, splice table, infeed servo, two or three rotary diecutting stations, scrap take-up station, outfeed servo, slitting and duplex winding. Optional processing, including flexo printing/coating for spot color or UV overcoat varnish, lamination, hot or cold foil capability are provided as modular add-ons.

“We are a lean company and have invested in four CNC multi-axis machining centers,” adds Giles. “This allows us to have complete control over mechanical components fabrication and schedule, and additionally allows us to realize economy of scale in our manufacturing process, which helps us drive system costs down. Our machine pricing and delivery schedules are consistently favorable in comparison to our competition.”

In 2014, Aztech launched the Matrix Modular Digital Finishing System. The laser finishing equipment, based on LasX technology, is a modular, expandable laser cutting system for clients that specialize in providing short run, variable printed labels. “There always have and always will be upgrades and changes required based on client feedback relative to process and product direction,” explains Giles. “These changes can be obvious, such as width and speed requirements, or more subtle changes required to incrementally improve a process or product. We are currently redesigning our flexo printing system and some of our rewind drive control system.”    
www.aztechconvertingsystems.com

Chase Machine & Engineering
Chase Machine & Engineering, based in West Warwick, RI, USA, is an equipment manufacturer that originated in 1954. The company primarily serviced the textiles industry during its early years, and in the early 1970s, Chase designed and built its first ultrasonic slitter for a narrow woven web manufacturer. Chase became more diverse and now designs and builds custom web handling equipment for products, such as hollow fibers, that are .040″ in diameter, used for blood or liquid filtration, to 144″ wide ultrasonic laminators and slitters used to process woven or nonwoven webs.

Chase provides a diverse product line of slitting and winding equipment. “Regardless if our customers are interested in conventional slitting methods like score, shear and razor or non-conventional methods such as ultrasonic or laser, Chase has the experience required to integrate these technologies into continuous web processing equipment,” says Guy Gil, national sales manager, Chase. “We also design and fabricate single and dual position center drive rewind equipment utilizing a variety of tension control devices, such as torque, dancer or load cell tension control, on common or differential rewind core shafts.”

Gil says Chase’s flexibility and employees give it an advantage in this marketplace, as its core team has been together for over 20 years. “Our advantage is that we can design and build a system to our customer’s exact specifications or requirements,” he explains. “We do not have a ‘take it or leave it approach’ with customers. We are also one of the leading machine experts in integrating Ultrasonic Technology into continuous slitting processes with over 45 years of experience.”

In addition, Chase offers a Materials Application Lab, which customers can access to test their materials to determine what features may be required. Information, such as processing speeds, lamination or slit quality, edge guidance and tension requirements, can then be determined and addressed in the design phase. In the future, Gil anticipates materials becoming lighter and stretching more, with the challenge becoming faster processing speeds. “With the advancement of AC and servo drive technology, controlling speed and tension has become easier,” he adds.
www.chasemachine.com

Kocher+Beck
Founded in 1965, Kocher+Beck offers the UR Precision line of automatic splicing unwinds, automatic transfer rewinds and automatic transfer matrix rewinds in order to automate printing presses or other converting lines. The company provides nonstop feeding of web materials to printing and converting machinery.

According to Ward , Kocher+Beck’s machinery offers flexibility and simplicity. All of its machines also have the ability adapt to new presses and provide an integrated system. In addition to this networking feature, the equipment’s computer system allows for data collection, which is an important part of quality control.

“Our rewind incorporates a unique and proprietary transfer mechanism that uses a scissor cut knife,” explains Ward. “This provides many benefits, but primarily it means that we can cut virtually any material without any machine adjustments.”

Kocher+Beck runs a PC-based operation on a Linux platform, equipped with the latest networking technologies – including a high-end HMI – to generate the fastest possible response times. The company’s goal is to leverage modern control systems for high-quality performance. The machines also have a button that connects the customer directly to Kocher+Beck for trouble shooting and maintenance queries. Support can be provided remotely, as well.

“You push the button and the machine calls our computers,” explains Ward. “Then we have full access to see error messages, we can tell when the press is up and running again, we can see all of that. If they’re winding a roll, and they’re not real happy with the quality of the roll, we can look at that and say, ‘Here’s your problem; you didn’t set up your torque curve correctly.’ We can also offer every software update available.”

Instead of a bump and cut system, Kocher+Beck utilizes a knife that is accelerated to match the wind speed, and it then makes a scissor cut. Two opposing blades make this scissor cut as it cuts straight across the web. The straight end is then attached to the core, which the company attributes to its flexibility. “If you can run it through the press, we can cut it,” adds Ward.

The UR 440 is compatible with standard press widths from 11″ to 17″, and a maximum web width of 17.5″. The equipment splices up to 500 fpm with a tension range of 40-90 pounds. The maximum roll diameter includes 24″, 30″ and 40″, with a core diameter base of 3″.

Additionally, Kocher+Beck’s equipment contributes to sustainability and waste reduction efforts. “The UR Precision equipment has eliminated as many of the wasteful pneumatic functions as possible,” adds Ward. “Our machines leave a very small carbon footprint compared to other systems on the market. Our unique Tape Saver feature on our rewind reduces adhesive consumption and allows for less waste at the core.What you see from us is really geared toward the label business, and it is to keep those printing presses running as much as possible. Sometimes that could even be one, two or three roll jobs, and sometimes it’s 30 or 40 roll jobs that customers have,” says Ward.
www.kocher-beck.com

Martin Automatic
Martin Automatic, headquartered in Rockford, IL, USA, delivers automated splicing with precise tension control for roll-to-roll processing. The company manufactures inline automatic transfer rewinders for nonstop winding on the press, which is equipped with slitting capability.

According to Gavin Rittmeyer, vice president of sales and marketing, Martin Automatic offers inline slitting where the parent web comes into a machine, it is slit, and then the result is multiple daughter webs.

“We’ve developed a winding technology that allows us to slit inline and rewind slit ribbons inline in a single position in spindles, and make the automatic transfer,” exlpains Rittmeyer. “That is extremely difficult, and we’ve done that developing new and specialized hyperbolic and parabolic tension profiles. Lay-on roller technology is how we use that in the winding process. We chose to fit a gap or vacuum in the market that is automatic winding of jumbo rolls that can also slit inline.”

The LR Series features a two spindle, recirculating turret-style rewinder, where operators have maximum flexibility in regards to automation. The rewind can then function smoothly and transfer the material to the core and then unload the roll, all without the presence of the operator next to the machine.

The machinery has the capability to slit 14 ribbons on a 16″ wide web, as it did during a recent tea bag tag application. The slit web was 1″ in width and included edge trim. Martin Automatic provides shear slitting, where the anvil can be removed and replaced easily, leaving the operator only to reset the slitter blades to the correct anvil position. Stationary or quick change anvils are available, which allows for offline finishing. Martin Automatic also provides bold roller technology for ribbon separation. This ensures that the ribbons don’t become entangled or overlap as they wind on their individual cores. Some of Martin’s higher-end rewinders feature laser-assisted core setup.

The company’s equipment can be run with pressure sensitive labelstock and film-based materials, including toothpaste tube laminate, ABL, PBL, single-ply paper and other substrates for flexible packaging and flexo-based materials. “We can slit and rewind inline complex premium labels that have complex figures and printing applications; for example, screen printing,” says Rittmeyer.

“Many of the advantages with the Martin Automatic line have to do with our continual entrepreneurial approach toward operator ergonomics, and ensuring that converters and business owners have the highest rate of return on investment that they can possibly get,” adds Rittmeyer. “That is through very practical, innovative features such as automatic roll unload, the single button push arming of the machine, making the functions of the machine as intuitive as possible and open air architecture. One of the things I tell every customer is, ‘We’re going to spend your money like we would want you to spend our money,’” Rittmeyer concludes. “We want to take extreme care of them.”
www.martinautomatic.com

Prati
Since 1973, Prati has specialized in post-print finishing, inspection, diecutting, matrix stripping, rewinding, cutting and overprinting. Based in Faenza, Italy, the equipment provider has sold more than 2,500 machines worldwide. According to the company, its focus is centered on growth, service, flexibility and innovation.

Prati has most recently released the Jupiter WF slitter inspection rewinder, which is intended to cut time and overhead from each process. Its software is designed for fully automated quality control and corrective action. The company states that the Jupiter WF enables converters to streamline production, improve efficiency, reliability and quality. In addition, the machine’s automation lessens the risk for operator error.

The Jupiter’s WizArm multitask web feeder allows for the rewinding of films on one shaft only, thus saving time by separating rows and positioning them on the cores for a new operating cycle.

Prati also offers the Saturn for high-speed slitter inspection rewinding. It features new generation motion technology and a self-sharpening slitting system. The disengageable shear slitting system comes equipped with four rotary knives and counter-knives, capable of cutting self-adhesive paper and plastic labels, as well as UPM Raflatac PP30 and Avery Dennison PET 23µm liners, booklet, tube laminate, Alufoil, Tyvek, cardboard and multilaminate.

The machine’s fully modular concept enables the addition of options like a 100% inspection camera and inkjet systems. Its make-ready function allows all systems to run simultaneously. 
www.praticompany.com

Rotoflex
Rotoflex, founded in 1973 as a rotary tooling company, offers offline finishing systems, including slitting, label inspection and advanced diecutting. The company features the VSI and VLI lines of inspection slitter rewinders.

The VSI Series eDrive, a web transport system, has the latest inspection and finishing technologies and runs at maximum speeds up to 1,000 fpm. The compact footprint is provided in 13″ and 17″ widths, and is designed for demanding production environments. The Rotoflex VLI has expanded capabilities for more advanced applications and high-speed production. It is suitable for film, film packaging and other tension-sensitive materials. Its versatility makes it useful for various applications and substrates. Ranging in widths from 13 – 28″, the equipment is able to accurately slit and rewind at speeds up to 2,000 fpm, and streamline the finishing workflow.  Standard options include a semi-automatic turret and multiple vision inspection systems, as well as full security inspection.

“Rotoflex research and development teams have designed the exclusive URC 2.0 and eDrive 2.0 systems, which guarantee consistent, precise rolls,” says Kevin Gourlay, vice president, Rotoflex. “The URC 2.0 control system supports independent multi-lane count, 100% missing matrix and label detection (MMLD) and precise fault placement. Another component of URC 2.0 is the Report Management System (RMS), which allows production managers and supervisors the capability of viewing real-time production data from multiple machines through a single, wireless interface.”

The DSI highlights the company’s offline diecutting equipment and supports the efficient production of blank labels and sheeting. The DLI product line is a modular system supporting multiple web widths and register controlled diecutting with a wide variety of optional components, including coating, hot and cold foil, booklet insertion, punching and many others. “Rotoflex will continue to push the envelope in providing equipment that supports an efficient pressroom workflow,” adds Gourlay. “We have immediate plans to release a horizontal rewinder to support our clients who prefer that machine orientation and will more fully support digital press outputs with our Vericut3 digital finishing system. In addition, we will enhance our existing products to more efficiently finish the extremely demanding requirements of advanced security and pharma applications.”       
www.rotoflex.com