Web Tension and Guiding
Advancing Precision in Non-Stop Winding for Label Production
By Sonia Crosas, Non-Stop Winding product manager, A B Graphic International
UNDERSTANDING THE ROLE OF TENSION CONTROL IN LABEL MANUFACTURING Consistent web tension is a crucial factor in label production, directly aff ecting print quality, die-cutting precision and overall operational effi ciency. Eff ective tension control becomes even more essential as the demand increases for higher throughput and tighter tolerances. Variations in web tension can lead to web wander, wrinkles, misregistration and, ultimately, label waste. Factors such as splicing dynamics, changes in acceleration and roll inconsistencies typically infl uence these issues. Tackling these challenges necessitates both mechanical precision and real-time control strategies.
ENGINEERING SOLUTIONS FOR STABILITY AND ACCURACY
A B Graphic International (ABG) has developed Non-Stop Winding systems to address these specifi c challenges. Central to the system design is a dancer roller mechanism engineered to reduce friction and maintain consistent web tension during operation. ABG’s in-house R&D team created the mechanism as part of a closed-loop control architecture that includes servo-driven components for automated tension adjustments.
The Automatic Servo Unwind (ASU) extends these capabilities by utilising advanced servo motors and sensors that continuously monitor and
adjust tension throughout the unwind process.
HIGH-SPEED SPLICING WITH MINIMAL DISRUPTION
The systems maintain tension stability and facilitate effi cient material transitions. By using a rotary knife cutting mechanism, the unwinders can achieve splicing speeds of up to 200 metres per minute, with a splice cycle completed in about 1.85 seconds. This ensures minimal production interruptions, reduced operator intervention and improved line uptime. Tension
ranges can be adjusted between 30 and 150 newtons, allowing the system to handle a variety of substrates and accommodate diff erent press and fi nishing line requirements.
COMPATIBILITY AND INTEGRATION ABG’s Non-Stop Winding units are engineered for integration in a wide range of converting environments. They are compatible not only with ABG’s Digicon and Converter platforms, but also with various third-party digital and conventional presses. This versatility enables converters to improve existing production lines without substantial reconfi guration.
CONCLUSION Eff ective tension control is essential for maintaining production quality and effi ciency in label printing. By integrating advanced control technologies and robust engineering, ABG’s Non-Stop Winding systems provide a dependable solution to the challenges of high-speed label production. Their capability to deliver consistent performance with minimal operator input makes them a valuable asset in contemporary converting operations.
42
April 2025
www.convertermag.com
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