FIT for Converting Industries
Converting (industry)
Converting companies are producing new products from various raw-materials such as plastics, transfer adhesives and tapes, silicones, foams, rubber, films and foils.
Materials such as paper, plastic films, foils and fabrics are often manufactured in long, continuous sheets which are rolled up for convenient handling and transport.
These rolls can vary considerably in size and weight - from 2 to 200 inches in width and up to several tons in weight. The end customers use these continuous
rolls of materials, also called as webs. The materials are put through processing machines such as printing presses, laminating and coating machines, and slitting
lines. These machines are forming the source materials into another semi-finished form or to final products. For example, the processing machine could cut a thin
plastic film into strips and weld the edges together thus producing plastic bags. This kind of processing is called web processing.
Typical manufacturing processes are coating, laminating and printing. The coating technology can use hotmelt-, gravure-, curtain- and die coating. The most commonly used printing technologies are based on flexographic and rotogravure printing. Both printing processes are suitable for rapid roll-to-roll processes.
Many converting companies process large diameter reels or large widths, since this increases the processing efficiency and minimizes replacement. After the converting process the rolls are cut by slitting them to smaller rolls so that they are easier to pack and that they are more suitable for further processing.
Web edge control is an important part of the manufacturing process, since the tracks during processing tend to run off the track. To avoid these problems, our engineers have developed a variety of automatic web guiding systems which ensure accurate tracking of web edge and by so reduces the waste. Web guiding system are typically mounted exactly where a crucial stage in the processing starts. For example web guiding system can be installed just before a printing station on a printing press to ensure flawless outcome. .
Each type of web control system uses sensors to monitor the web edge position and each has actuators to bring the running web mechanically back on track if the sensor detects
a drifting movement off the set track. The servomotors can be pneumatic or hydraulic cylinders, or electromechanical devices. Since the web - mainly on the edges - can be very
vulnerable, non-contact sensors are always used.
Since the web - mainly on the sides - can be very vulnerable, non-contact sensors are used. These sensors may be pneumatic, optical, ultrasonic or infrared sensors. The
control system has to convert the signals of the sensor in a way that the motor is moved. Many of these control systems today are electronic and they use amplifiers to
convert the signals. The sensors then drive special servo motors, which have a spindle nut or a ball screw. The latest web guiding systems have a controller via
touchscreen, to simplify the setup procedure. Some web guiding systems are designed for the refining industry.
