In our first blog post about auto-splicing technology, we explored Contiweb's rich legacy in this area, highlighting the innovation, durability, and comprehensive support that distinguish us in the industry. Now, we’ll delve deeper into the pivotal role Contiweb’s auto-splicing technology plays in web offset printing—a fast-paced, high-volume segment where operational efficiency hinges on the ability to make seamless reel changes without interrupting production. Contiweb’s auto-splicers, known for their reliability and precision, are crucial for maintaining this level of performance.
Splicing at impressive speeds
Web offset printing operates at impressive speeds, typically ranging from 8 to 15 meters per second (25 to 50 feet per second). Due to this rapid pace, paper reel changes are required every 20 to 25 minutes, and efficient reel changes are essential for avoiding costly downtime. This is where Contiweb’s flying pasters come into play. Specifically designed for the high demands of web offset printing, they perform reel changes "on the fly."
The "flying" aspect of these splicers refers to the seamless reel changeover process. As a reel nears the end of its run, the idle reel is accelerated to match the exact speed of the nearly depleted reel. Once both reels are synchronized, the splice is made on the fly, allowing the printing process to continue uninterrupted. This precision is critical in preventing costly downtime and maintaining high-quality output.
Contiweb has installed thousands of auto-splicers at web offset printers worldwide, firmly establishing itself as a leader in the field. One of the standout features of Contiweb's splicers is their design, specifically suited to the high-speed demands of web offset printing.
The configuration not only enables non-stop splicing at high speeds but also offers significant ergonomic benefits. Operator safety and ease of use are enhanced by this design, as it allows operators to access the splicer more easily, particularly during the splice preparation process. By reducing the physical strain associated with reel changes, the layout ensures a safer and more efficient work environment.
Easy preparation process
The splice preparation for automatic splicing is quick and straightforward, taking only 2 minutes to complete. It can be easily performed while production is ongoing, with minimal operator involvement. The process mainly consists of applying a linear adhesive tape for the straight-tape splice on the paper. The time required is limited to the actual splice preparation itself.
If multiple buffer positions for paper reels are available, the operator can prepare and set up several reels for automatic changeover. This allows them to focus on other tasks while the prepared reels are ready for seamless transitions.
Data from hundreds of installed systems show that Contiweb splicers and pasters consistently achieve successful splice or paste rates of over 99.7%. This results in low waste and maximum production time. Integrated infeed technology further enhances printing quality by accurately reducing web tension variations to less than 1% of the desired level in the outgoing web. User-friendly interfaces and extensive automation features also make Contiweb auto-splicers easy to operate. Splicing and pasting at any reel diameter are automated, and the splice preparation process remains simple and fast.
Full automation for seamless integration
One of the standout advantages of Contiweb’s auto-splicers in web offset printing is their ability to integrate fully with other press systems, creating a completely automated production environment. This level of integration simplifies both installation and ongoing operations, as there is no need for third-party involvement in the electronic or mechanical integration of the reel logistics systems with the press. This cohesive, integrated system boosts operational reliability and eliminates many of the common pain points associated with reel handling in high-speed production environments.
Reel logistics systems: automating efficiency
Another key advantage of Contiweb’s auto-splicers in this environment is their ability to integrate with comprehensive reel logistics systems, further optimizing the efficiency of reel handling.
Web offset printers face constant reel changes, which require both speed and precision. To address this, Contiweb has developed advanced reel transport systems designed to minimize operator involvement while maximizing reliability. These reel logistics systems can be customized to meet the specific needs of each press, offering standalone storage solutions and reel buffering systems that streamline operations.
In a typical system with four buffer positions, up to seven reels can be prepared simultaneously. The system is fully automated—once the reels are loaded into the buffer, no further operator involvement is required until all reels are used. The empty reels are automatically collected in a core container, allowing the press to run without interruption. This automation dramatically reduces the workload for operators, minimizes human error, and ensures that the press operates at peak efficiency.
The integration of these reel logistics systems with Contiweb’s non-stop flying pasters is seamless, with no third-party involvement required for installation or electronic integration. This creates a fully automated, turnkey solution that improves both productivity and reliability in web offset operations.
Durability and reliability in 24/7 operations
In the web offset printing industry, presses often run 24/7, making the durability of auto-splicing equipment critical. Contiweb splicers are renowned for their robustness, with many machines lasting for decades, even in high-demand environments. This longevity is a testament to our engineering expertise and commitment to quality.
However, even the most durable equipment requires regular maintenance to continue operating at peak performance. Contiweb offers Service Support Agreements designed to extend the lifespan of splicers and ensure optimal operation. Depending on the kind of agreement, these agreements include Remote Tech Support, Maintenance, original Spare Parts and even Equipment Enhancements to keep splicers up to date with the latest technology.
For clients concerned about aging equipment, particularly components that are no longer available, Contiweb provides a free Quick Scan of Obsolete Components, helping companies identify and mitigate risks associated with outdated parts. This proactive approach helps prevent costly downtime and ensures that equipment continues to perform efficiently for as long as possible.
Solutions for every stage of the equipment lifecycle
While Contiweb’s splicers are designed for longevity, there may come a time when equipment reaches the end of its operational life. When this occurs, Contiweb offers a range of solutions to meet the needs of its customers, including state-of-the-art new auto-splicers or Certified Pre-Owned equipment. This flexibility allows printing companies to choose the solution that best fits their budget and operational requirements, ensuring that they continue to benefit from Contiweb’s cutting-edge technology, even as their needs evolve.
Driving web offset efficiency
Contiweb’s extensive experience in auto-splicing, combined with its commitment to automation and innovation, has made it a trusted partner for web offset printers worldwide. With thousands of splicers in operation, the company continues to lead the way in providing robust, user-friendly, and highly reliable solutions that enhance productivity and safety.
By integrating advanced reel logistics systems and offering comprehensive support agreements, Contiweb ensures that its splicers remain in top condition for decades, delivering reliable performance even in 24/7 operations. For web offset printers, Contiweb’s auto-splicing technology is not just a tool—it’s a critical component of a seamless, efficient, and highly productive printing process.
Stay tuned for the next post in our series, where we will explore how auto-splicing plays a pivotal role in web inkjet printing, further expanding the versatility and impact of this technology across diverse printing environments.
