Film & Foil
Working with fi lm and foil materials in adhesive converting is never just about cutting
Written by ATyT
hin films stretch, foils can deform and multilayer constructions leave very little room for error. In this context, achieving consistent quality requires the right combination of machine capability and process control.
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At ATyT, as a specialised converter of technical adhesive solutions, this balance is at the core of our daily operations. On the production side, rotary die-cutting remains a key technology. In our case, we operate with a rotary system featuring three independent axes and dual unwind/ rewind shafts per cylinder, which gives us flexibility when handling complex adhesive constructions, laminations and die-cut solutions that we serve to multiple industrial sectors. This setup is especially useful when converting:
• Double-sided technical adhesive tapes, where alignment between layers becomes critical. When changing liners, films or foils, this technique becomes essential to ensure the correct performance of each component in the final application.
• Double-sided tapes with extended liner tabs, used to simplify application and playing a key role in automated processes, particularly in the cardboard industry. In these cases, managing different liner widths and materials is crucial to ensure the final product meets all customer requirements.
Among the different challenges we face, one common example is the production of parts with liner tabs. Poor tension control can cause the liner to shift, leading to inconsistent tab lengths. By adjusting each axis independently, we can stabilise the web and maintain accuracy
throughout the entire production run. However, even with advanced machinery, one of the biggest challenges in converting is repeatability. Two production runs of the same product can behave differently if setups are not properly controlled or if the materials used are not consistently verified against required specifications. This is where digitalisation becomes essential.
At ATyT, we rely on an ERP system like Odoo to ensure that every job is based on validated and reusable production data. In practice, this means:
• Machine parameters (pressure, speed, tension) are stored and reused, reducing setup time
• Operators follow standardised instructions, minimising variability
• Each production is fully traceable, making it easier to detect and correct deviations A simple but powerful example: when a specific double-sided tape shows cutting issues at higher speeds, that information is recorded. The next time the job runs, the system already suggests the optimal parameters, avoiding trial and error. These values are stored as part of the work instructions, ensuring a smooth and reliable production while preventing scrap and material loss.
The result is clear: less waste, faster setups and more stable production. Scrap caused by misalignment or incorrect pressure is significantly reduced, and operators spend less time adjusting the machine. In an increasingly demanding converting environment, combining precision rotary die- cutting with digital process control allows companies like ATyT to deliver consistent, high-quality solutions, run after run.
www.convertermag.com
April 2026
23
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