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The added value of auto-splicing in web inkjet

In our previous blog, we explored the vital role of auto-splicing in web offset printing. In this post, we focus on the application of this technology in roll-fed inkjet printing.

Contiweb has a long heritage in web offset printing, rooted in decades of innovation and expertise. Over the years, we witnessed and contributed to the industry's transformation into a high-speed, highly automated sector, driven by advancements in technology and the demand for greater efficiency. Today, we are observing a similar evolution in web inkjet printing. Digital printing presses are becoming faster, compatible with a wider range of substrates, and capable of delivering higher quality to compete with offset printing. However, this progress introduces new challenges.

Many of today’s web inkjet presses produce high-quality prints at speeds of 150 mpm (~ 500 fpm) or more. Depending on roll diameter and caliper, a roll can hold between six and twenty kilometers of paper (3.7 to 12.4 miles). At a print speed of 150 meters per minute, it takes between 40 minutes and 2 hours and 10 minutes to print an entire roll. The time required to change a roll can vary greatly, from an optimal 15 minutes to over twenty if the operator is multitasking. With a change time of 15 minutes and an hour needed to print a roll, this non-productive time can accumulate to 96 minutes—or 20% of available time—in an eight-hour shift. When printing roll-to-roll, the loss of production hours is even higher.

A press only makes money when it is printing

With 20% downtime, recouping a multi-million-dollar investment becomes challenging. When Druckerei Kyburz installed a cutting-edge production line featuring a Canon ProStream inkjet press 1800 and inline i-Web finishing equipment, they recognized this. Including a Contiweb CD-N Non-Stop Unwinder was a no-brainer. Kyburz, established for over 50 years, produces high-quality self-mailers and brochures for clients in Switzerland and neighboring countries. Patrick Kyburz, CEO of Druckerei Kyburz AG, states, “It is common for digital printers to perform manual reel changes. For us, as a web offset printer, this seemed very traditional. Our long-standing partnership with Contiweb, as we own five splicers, and our positive previous experience with Contiweb splicers that we use in our web offset printing lines, meant we were sure the machines would be a worthwhile investment.”

Kyburz Blog Web Inkjet

Another example is Seaway Printing in Wisconsin, USA. They delayed investing in a non-stop unwinder until their press reached maximum capacity. In 2021, they acquired their first web inkjet press, an HP PageWide T250HD. The press quickly hit its production limits, and soon, two shifts were no longer sufficient to meet demand. By replacing the mono unwinder with a Contiweb CD-N Non-Stop Unwinder and investing in a Muller Martini SigmaLine Compact, they dramatically increased productivity. Ian Hesling, Vice President of Seaway Printing, remarks, “With the Contiweb CD-N, we now complete a roll change in about 30 seconds. We’re gaining an extra hour and forty minutes each day across two shifts, allowing us to run more paper through the machine overall. These productivity gains enabled us to eliminate the third shift.”

Seaway Printing Blog Web Inkjet

Efficiency? Sure, but there is more to auto-splicing!

Investing in Contiweb’s auto-splicing seems like an obvious choice for efficiency reasons. But there is more. Another reason Druckerei Kyburz chose to add a Contiweb CD-N Non-Stop Unwinder was to reduce the risk of web breaks. The CD-N comes as standard with an infeed that controls the web tension. Proper web tension helps ensure that the substrate moves smoothly through the press, minimizing misalignment and defects. It also reduces the risk of web breaks and other disruptions that can lead to downtime and waste.

Patrick Kyburz states, “When finishing inline, it’s crucial that the line doesn’t stop, as each stop poses a risk of a web break. Many printers transitioning from sheet-fed are anxious about web breaks with automatic splicers, but the risk is actually much higher with manual changes. Contiweb systems are extremely modern and reliable.”

With a splice reliability measured at over 99.7%, independent of operator skills, the Contiweb CD-N Non-Stop Unwinder reduces concerns about paper web breaks, which can lead to extended production downtimes and significant operational challenges. This system enables seamless splicing regardless of press speed, paper diameter, web width, grammage, or grade, ensuring that production remains continuous without interruptions.

Enabling staff to focus on work that adds value

Continuous production without interruptions to change paper rolls can significantly boost a press’s productivity. Another key benefit of non-stop auto-splicing is the reduction in labor needs. By streamlining tasks, print shops can maintain the same output with fewer staff. This not only cuts labor costs but also helps address the growing shortage of skilled workers.

Many business owners view the shortage of skilled labor as the biggest threat to their print shops. As a result, it's essential to ensure that the limited number of skilled workers focus on tasks that require their expertise and add value, such as evaluating product quality and fine-tuning settings to achieve optimal results. By allowing skilled workers to engage in these high-impact tasks, companies can improve overall output quality, enhance customer satisfaction, and foster a more engaged and motivated workforce.

Automation could make all the difference

As digital printing technologies continue to evolve, the importance of efficiency and minimizing downtime becomes even more critical. Auto-splicing technology not only boosts productivity but also reduces labor dependency and minimizes risks such as web breaks. For companies like Druckerei Kyburz and Seaway Printing, investing in systems like the Contiweb CD-N Non-Stop Unwinder has proven to be a strategic advantage, allowing them to meet growing demand and remain competitive in an increasingly automated industry.

For businesses seeking to optimize their operations, embracing automation could make all the difference. Would you like to estimate the production hours you could gain through auto-splicing in your specific situation? Use our handy Savings Calculator to determine whether this investment will pay off for you!

Click here for an instant estimate of your earned production hours.