Reel & Roll Handling


Why the “best” splicing technology depends on the application By Pim Cornelissen, product manager, Contiweb


to keep the line running during reel changes, but they do so in very diff erent ways.


The main distinction lies in how the splice is made.


In a fl ying pasting system, the new reel is accelerated and synchronised to line speed before the splice takes place. Because both substrate webs are moving during the splice sequence, the splice is inherently created as an overlap splice.


Contiweb CB-N zero-speed auto-splicer with dual reel positions and accumulator.


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n web-based converting environments, reel changes can be managed either manually or automatically. In a manual setup, production must be stopped when a substrate reel runs empty or when a change to another substrate type is required. The empty reel is removed, a new reel loaded and the substrate threaded back through the process before production can resume.


While a manual reel change may seem straightforward, its impact on production is often greater than expected. In many plants, a reel change — including stopping the line, removing the empty reel, loading a new reel, threading the substrate and stabilising the process again — can easily take 10 to 15 minutes.


And the lost production time is only part of the story. Reel changes can also lead to additional substrate waste and extra operator involvement. As soon as a reel approaches its end, operators often need to interrupt other activities and focus entirely on the reel change. This aff ects both overall equipment eff ectiveness (OEE) and operational fl exibility on the production fl oor.


TWO DIFFERENT APPROACHES TO NON- STOP SPLICING


Where continuous production is required, non- stop auto-splicing technology is a well-established solution. In continuous converting applications, two main methods are used today: fl ying pasting and zero-speed splicing. Both technologies are designed


In a zero-speed splicing system, the new reel remains stationary during the splice while an accumulator or festoon temporarily feeds substrate into the line. Because the splice is made under stationary conditions, both overlap and butt splices can be created, depending on the application and system confi guration.


PROCESS REQUIREMENTS DETERMINE THE TECHNOLOGY


Which technology is most suitable depends heavily on the application. Factors such as production speed, reel dimensions, substrate characteristics and downstream process requirements all play a role in the selection process.


Flying pasting is often used in applications processing large and heavy reels at high production speeds. However, these systems can only create overlap splices. Even though the overlap section in fl ying pasting systems can be shortened using a tail cutter, the splice can still become too thick for certain converting applications.


Zero-speed splicing, on the other hand, can


off er advantages where splice thickness is a critical consideration. Systems that create butt splices may be preferred in processes where even a small increase in substrate thickness could aff ect downstream operations such as laminating, embossing, precision coating, slitting or winding.


SELECTING THE RIGHT SOLUTION When evaluating non-stop auto-splicing solutions, it is important to look carefully at the specifi c requirements of the production process. Production speed, reel dimensions, substrate characteristics, splice thickness and downstream process requirements can all infl uence which technology is the best fi t.


Illustration of an overlap splice and a butt splice 44 May/June 2026


Discussing these requirements with an experienced auto-splicing specialist that understands both fl ying pasting and zero-speed splicing technologies can help converters make a balanced decision based on the actual application rather than a preference for a single splice principle.


www.convertermag.com


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