Get the max out of your web inkjet press
Digital inkjet printing has always required good uptime to support profitable businesses, which has never been more crucial. Some print companies change reels as frequently as every hour. Either a reel is empty at the beginning of the press line, or full at the end – when inline finishing is not employed – or a new job requires different coating on the paper, or web width, or weight. This has huge impact on the uptime of the press line, drastically reducing speed and capacity.
Contiweb’s non-stop unwinders and rewinders can splice paper reels of different weight, web width or coating without production stop.
Fully automatic rewinding without production stop
The CR-N rewinder is fully automatic, with the zero-speed operation ensuring perfectly rewound reels without interrupting production. With the press in production, the running and new web are brought to a halt during the splice cycle, when the press is fed from the integrated festoon. The automatic splice can be made at production speed, at any reel diameter and at any time. Fully wound reels can be unloaded and cores prepared during production. A lap splice is standard, and the CR-N can optionally perform one or two-sided butt splices.'
Shafts on the CR-N can be taken out and must be inserted into the core of the new reel. The arms can move the shaft up and down, so that reel loading and unloading can be done from the floor. No crane is necessary.
The CR-N offers additional optional functionalities, including integrated electronic web tension control at outfeed, web guide, and slitter before the splice. With the integration of the slitter, printers can slit the web in ribbons with variable web widths before the splice, without interrupting production. While slitting, it is possible to splice and switch from one reel to the next.
- Non-stop winding saves considerable production and labor hours
- Change reels and prepare splices during production, so avoiding production stops
- Preparing the splice is very easy and takes only two minutes. The splice performance is regularly and repeatably 99.8% or higher
- You can splice over to papers of different web widths, coatings and weights. This is very useful for short, fast-changing jobs. It is also easy to use rest reels, and there is no restriction on the diameter of the new or used reel for splice performance
- The CR-N non-stop rewinder allows you to make a splice whenever you want without stopping production. If some jobs use the same paper but require different finishing, it can be easier to rewind them on different reels
- If your press can accept it, Contiweb non-stop winding equipment sends a signal to your press when a splice is coming. This way the press can lift the print heads. The Contiweb equipment will even send a signal if it recognizes a splice made by the paper mill! Contact Contiweb for more information.
- The lift arms of the Contiweb equipment can move up and down, allowing the reel to be loaded from the ground. This operation is ergonomic, and requires no lifting crane
- Additional advantages are: fewer mistakes when preparing the splice, less chance of losing the web completely out of the engines (time pressure of production). Less waste by cutting unnecessary white paper, fewer startup problems, energy savings by quick change over.
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How does non-stop winding work?
Contiweb’s non-stop winding equipment consists of a CD-N unwinder and CR-N rewinder. The CD-N unwinder can splice a fresh reel of paper to an expiring reel without having to stop printing. It operates while the expiring reel and the new reel are both stationary. The press, however, continues to print. This is achieved by expanding a festoon in the device, above the paper reels.
During splicing, the press can draw from the paper, which snakes its way through the fully-expanded festoon. The expiring reel is stopped, the new reel is spliced to it, and the new reel is expanded to press speed. This collapses the festoon, which is expanded again the next time a splice needs to occur. The whole process is fully automatic.
At the end of the press line the CR-N rewinder works the other way round. When a paper reel is nearly full, the festoon is filled with printed paper, allowing the rewinder to halt the full and empty reels, cut the paper, and splice the web to the empty reel.
Case study Rotomail
As the demand for digital printing and the need to diversify print offerings intensifies, the need for quality printed products and higher productivity grows.
When Rotomail installed a new premium-performance inkjet printer in 2016, Contiweb’s modular CD Unwinder and CR Rewinder systems opened the door to increased efficiency, speed and time-savings.
Fill out the form to receive the case study.
Investment in non-stop winding equipment pays for itself
The investment associated with the purchase of non-stop winding equipment is often recouped faster than expected. The operating costs of a web inkjet printing press quickly amount to several hundreds of Euros per hour and you can only recoup these costs if the press actually prints - not if it stands still. In addition, time is freed up for the operator to do other work.
Rob Bosman, Senior Sales Manager at Contiweb, has made dozens of calculations together with his customers and almost always the customer came to the conclusion that non-stop is also interesting for them.
Read his blog and find out why.