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Web Handling & Converting

Blogmaster: Dr. David Roisum

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Winding

17

Roll Handling Tattle-tales

Posted by David Roisum on May 17, 2012
Ever got a returned roll from a customer?  Looks nothing like when it left the winder.  Looks truly beat up.  Who dunnit?  Handling by your people, trucking/rail, your customer and what was the offending element?  Simple, put a roll handling tattle-tail in the core.  Th...

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Posted in: (Other) Converting, Winding
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15

Semi-Intelligent and Truly Intelligent (Forklift) Clamps

Posted by David Roisum on May 15, 2012
Semi-Intelligent and Truly Intelligent (Forklift) Clamps
There are truly stupid clamps that have only two settings:  open and closed.  The closed pressure is set conservatively so that no load ever gets dropped even if that means crushing the small roll or box.  Semi-intelligent clamps use lookup tables to set clamp pressures based on lift ...

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Posted in: Winding
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10

Core Crush - Product Redesign

Posted by David Roisum on May 10, 2012
A continuation of previous post.  After you have done everything appropriate and possible by either increasing (Type III) or decreasing (Types I and II) all of the winder TNT’s, the problem is no longer a winding problem in the sense that there is no winding solution.  We must consid...

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Posted in: Winding
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08

Core Crush – Three Defects for the Price of One

Posted by David Roisum on May 8, 2012
Core Crush – Three Defects for the Price of One
Core crush is not one defect, but three totally different defects that share the same name (and final outcome). Core Crush Type I – Here the loads that cause the core to give way come from winding (tensions converted to) pressures.  Here, the core fails during or shortly after winding.&n...

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Posted in: Winding
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03

High edges, narrow layon rollers and other confusion

Posted by David Roisum on May 3, 2012
Q: A colleague of mine recently stated that use of a lay-on or rider roller that is not as wide as the web is 'common practice'. He sees this as a form of 'winding optimization', whereas the word that I would use is more like 'accommodation'.  We are winding a delicate .001" thick film that is ...

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Posted in: Nips, War Stories in Web Handling, Web Manufacturing, Winding, Wrinkling & Flatness
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20

Profile and Winding Tightness

Posted by David Roisum on April 20, 2012
Profile and Winding Tightness
The winder TNT settings plus material properties determines the AVERAGE winding tightness across the width.  Profile variation determines how the tightness is distributed.  Seldom in the real world can we vary average winding tightness by much more than 2:1, even if we throw all of the kno...

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Posted in: Measurement, Problem Solving, Web Manufacturing, Winding
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18

Weight Profile Detection

Posted by David Roisum on April 18, 2012
Perhaps the most useful profile for troubleshooting is (basis) weight.  Weight (caliper, density, gage, thickness etc) variations across the width are one of the most universal causes of waste/delay/trouble in the web industries.  Unfortunately, weight profile is difficult to measure with ...

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Posted in: Measurement, Problem Solving, Web Manufacturing, Winding
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03

Worst-Case:? - Moderate Misses

Posted by David Roisum on April 3, 2012
Which is a worst-case reliability for missed transfers on a turret winder or unwind:  90.0%, 99.0% or 99.9?  Surprisingly, it may very well be that 99% is worse than 90% and it has to do, as everything should, with economics.  If you miss 1 in every 10 transfers, you will not suffer f...

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Posted in: Problem Solving, Winding
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26

Speed Limits - Web Handling

Posted by David Roisum on March 26, 2012
Speed Limits - Web Handling
There are only two speed limits in web handling that I am aware of.  The first is air entrainment.  This is easy to counter on rollers by roughening them to give them air-handling capabilities.  (You may have to avoid annular or spiral grooves for very thin products, as they might ten...

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Posted in: Design, Rollers, Winding
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22

Wound Roll Wrinkles – Top of the Roll

Posted by David Roisum on March 22, 2012
The top of the wound roll is especially wrinkle prone.  Gage variations build to make wound roll geometries that are orders of magnitude cruder than rollers.  The nip and thus tightness of many surface winders increases thus making tighter wound rolls that are less able to cover up manufac...

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Posted in: Web Manufacturing, Winding, Wrinkling & Flatness
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Blogmaster

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Dr. David Roisum

Dr. Roisum is a well-known authority in the area of web handling and converting. He has authored seven books, including Winding, Rollers and Web-Handling and has coauthored or edited several others. He was a technical editor for Converting Magazine with a monthly column entitled "Web Works." An accomplished professional speaker and instructor, Roisum has been praised for his skill at translating highly technical information into a common sense practical reference. Dave has been honored by TAPPI with their Finishing & Converting Division Award, Thomas W. Busch Prize and Finest Faculty awards and is a TAPPI Fellow. Dave received his Ph.D. from the Web Handling Research Center where he later became an Industrial Advisory Board member.

Dave has worked for the Beloit Corporation as a designer of winding machinery and later as a manager of research, and for Kimberly-Clark as a converting expert serving all business units. He is now a principal of Finishing Technologies Inc., providing consulting services to more than 300 clients who convert or manufacture: paper, film, foil, nonwovens, textiles and many other materials. He has accumulated much practical experience working in nearly 1,000 plants over the course of more than three decades.