Core Competencies: The base for quality winding

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1 Core Competencies: The base for quality winding 2005 AIMCAL Fall Technical Conference October 16 19, 2005 Myrtle Beach, SC Web Coating - Laminating Section Paul Roth VP / Director Sales Appleton Mfg. Div, Productive Solutions

2 Goals Increased your core competency to help facilitate your web handling and product quality We ll delve into How they are made Issues in core production Handling & storage Core cutting options Page 2

3 What & Why Round Tubular shape Paper Plastic Metal Page 3

4 What - Purpose Foundation of the wound product Non-woven fabrics Label & tab stock Tape Paper Light gauge metal Plastic film Or any other product found in a roll form Page 4

5 Why Start a roll Drive the roll Supports/protects the product during shipment Aids in handling Assists in the unwind Page 5

6 Where are they found Winder Rewinder Unwind Often forgotten until they are missing and cause downtime or missed shipments Page 6

7 Core Materials Iron/steel Shipped with the product and returned Accounting and customer relations associated with charges credits & tracking caused them to fall into disfavor Still used in house and seldom shipped to customer Page 7

8 Core Materials - Plastic Small volume but gaining acceptance Readily reused Small diameter applications where they become apart of the customers equipment Page 8

9 Core Materials - Paper Spiral Convolute Plys wrapped around a shaft (mandrel) Desired wall stock dictates number of plys Bound with glue Mainly round but other shapes are possible A single sheet or paper is wound up around a form Wall dictates how long the paper is Has single seam Used where smooth surfaces are desired Page 9

10 Spiral Winding Process Rolls are called plys and can be made of different paper cost & performance Expensive kraft inner & outer plys Less expensive plys recycled short fibers used for interior plys Inner fly fed from opposite side and has its own glue applicator Page 10

11 Production Method - Spiral Rolls staged on back stands Page 11

12 Production Method - Spiral Fed through tension devices where glue is applied Page 12

13 Production Method - Spiral Combination of paper and glue result in the wall stock Winder designs have evolved Purpose drive and compress the composite together Plys wound around mandrel that sets ID Page 13

14 Production Method - Spiral Winder section Page 14

15 Production Method - Spiral Plys run under belt and continuously produced then cut to length. OD set by number of plys and thickness of paper operator dependent Page 15

16 Production Method - Spiral Cutoff Page 16

17 Production Method - Spiral Composite allowed to cure then cut to length. Saw VS knife cut off techniques Page 17

18 Production Method - Spiral Stacking Packing Page 18

19 Production Method Convolute Sheet fed into machine Glue and hot melt strip applied Grasped by mandrel and rolled up Produced in fixed widths OD set by caliper of paper Composite ejected and allowed to cure then packed for shipment to customer Page 19

20 Convolute Winders Page 20

21 Post Production Finishing Recutting Grinding, Coating Page 21

22 Finishing Options Starter plys Slitting Page 22

23 Finishing Options Beveling/Chamfering Plugging Page 23

24 Finishing Options Skiving Notching Page 24

25 Quality Testing Methods Composite Can & Tube Institute (CCTI) CT 101 CT 102 CT 103 CT 104 T-5 T-108 Measuring Wall thickness Measuring Inside Diameter Measuring Inside Diameter Measuring Length Ordering/Storing Mill Cores Side to Side Crush Page 25

26 CT 102 Measuring ID Measure four diameters using an inside micrometer Average results Page 26

27 CT 104 Measuring Length Height gage Flat stone Printer Flat bar Page 27

28 Quality Test Methods And there s are more CCTI or (800) Page 28

29 So What!! Why should I care? Knowledge is king Converters do not need to be experts Know the quality issues core producers face and how those issues affect your quality and scrap. Quality matters Page 29

30 Quality Matters OD/ID Tolerances Winding mandrel Stable mandrel and OD controlled by varying plys & glue Tapered mandrel and tolerances transferred to the ID. Page 30

31 Quality Matters Variations affect winding tension and recutting process Ensure your specify which is important to you and control them Is it the ID or is it the OD that is important. Page 31

32 Quality Matters OD/ID Tolerances - Continued OD variances Poor web tension in surface driven winders ID variances Loading cores on shafts & Chuck spin out Be sure to control your raw material If you accept poor quality you ll get it over and over and over again Page 32

33 Quality Matters Straightness & Warp No good standard just how to measure it CCTI T-121 does not address limits Automation demands consistency Automated core loaders & cutters 7 degree decline No greater than ½ gap in middle Page 33

34 Quality Matters Roundness Ovality caused by handling & storage More of an issue with larger diameters Caused by weight of stack flattens lower cores that are not fully cured Page 34

35 Quality Matters Delamination of inner and outer plys Causes issues with chucks and recutter Tabbing on ID Dog ears on OD Page 35

36 Quality Matters Types of delamination Inter-ply paper failure Intra-ply composite failure Results of poor ply bond Inner liner completely torn out High unwind speeds separate outer ply Page 36

37 Quality Matters Recutting problems Delamination of cut cores Shortest cut equal to or greater than wall thickness Page 37

38 Precuts VS On-site Cutting Make VS Buy Buy precuts Cut on JIT basis Factors to consider Inventory space for core storage & cost Procurement costs precuts VS parent cores Cut length tolerance Page 38

39 Precuts VS On-site Cutting Factors to consider Flexibility of supply Frequency of order changes Waste due to damage, shrinkage, obsolesce Floor space storage of precuts VS parent cores Commit to labor component Another process to become familiar Page 39

40 Precuts A Closer Look Advantages Lower capital costs Possible less manning One less process to manage Page 40

41 Precuts A Closer Look Disadvantages Close frequent communication with supplier Increased inbound freight & setup costs Inventory shrinkage - two types Loss of units and scrap Premium for precut cores Page 41

42 On-site Cutting A Closer Look Advantages Quicker response to changing demand Lower costs Staffed by indirect labor person Flexibility in selecting a core supplier Page 42

43 On-site Cutting A Closer Look Disadvantages Capital Investment Staff to run cutter Waste removal Page 43

44 Cutting Methods No matter where cores are cut, cutting method dictates cut quality and can cause issues in the converting process Page 44

45 Saw Type Cutters Remove material 1/8 to 3/16 Square cut to core wall Not sensitive to core diameter Creates dust/debris collection system Noisy suppression enclosures Page 45

46 Knife Type Cutters Do not remove material parts core Minimal dust/debris Slight bevel less than half the knife thickness Page 46

47 Knife Type Cutters Free wheeling-rotating Crush or score cuts as it parts core More porous pulled fibers Brake causes drag slower cutting speed Page 47

48 Knife Type Cutters Fixed Knife Slits core virtually dust free Polished burnished edge Page 48

49 Cutting Methods Batch Semi, Automatic & Programmable Cuts from parent are all same length Less costly equipment Greater chance for tolerance stack length Greater chance for OD variation Possibly more waste Page 49

50 Cutting Methods Set Cutting Programmable only Improved cut length accuracy Less waste especially when parent length = slit width Crucial when using surface winding Programmable cutters are more costly Capable to communicate with production control computers Page 50

51 Cut Quality Cut core quality is part of your image and impacts your daily operation Burr, Dog ears tabbing & delamination Dependent on several factors Type of cutter Core Construction Core diameter Page 51

52 Manual Cutters Page 52

53 Semi-automatic Cutters Page 53

54 Automated Cutters Page 54

55 Programmable Cutters Page 55

56 Auto Handling Devices Page 56

57 Sophisticated Systems Page 57

58 Summary To avoid problems know what matters to you and your customers process Control variables Core ID/OD, cut length tolerances Monitor critical elements Decision to buy precuts or cut in house Page 58

59 Credits Appleton Mfg Div Avery Dennison Berlin Foundry Composite Can & Tube Institute CoreLink CoreTech Dusenbury John Eppler Machine Works Hayes Manufacturing Paco Winders Spack Systems Spiral Tech Page 59

60 BACK TO LIST

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