AIMCAL Europe 2012 Web Handling Conference

Prague, Czech Republic

Guidelines for Selecting the

Best Winding Process for
Your Products
R. Duane Smith
Product Manager – Specialty Winding
Davis-Standard, LLC
There is a lot of Science that goes into
Winding

The Winding Principles are well

established and have been proven and
modeled at the Web Handling
Research Center at OSU*
*Oklahoma State University, Stillwater, Oklahoma, USA
This presentation will discuss:
• These Winding Principles
• How they are used on different types of
winders.
• Present the Product Parameters that each
type of winder is best suited for.
Goal of the Presentation-
To assist you in determining the best type of
winder to use for consistently producing
quality, defect free rolls of your web material
Roll Hardness
The Critical Factor in Determining
the Difference Between A Good Roll
& A Bad Roll
Secret to building a Good Structure
• Build a good solid foundation.
• Then wind with progressively
softer roll hardness
Proven Fact:
As Roll Winds - Inwound Tension Or Residual
Stresses Build Up Inside The Roll
If Stresses Become Greater As Roll Winds Larger -
Inner Wraps Towards The Core Will Loosen &
May Even Go Into Compression
This Causes Rolls To Contain Defects Such As
Telescoping, Buckling &/or Starring
ROLL HARDNESS MUST BE
PROFILED TO PREVENT THIS!
 Roll Hardness Profiles
Roll Hardness vs. Diameter

120
100
Hardness Taper

80 Ideal Hardness Taper

60 Maximum Hardness Taper
Minimum Hardness Taper
40
20
0
Core Diameter Full Roll
Suggestion on how to remember the
Winding Roll Hardness Principles
The Three Winding Principles
used for consistently Winding
Dynamite Rolls are:
T.N.T.
T.N.T. Winding Principles :
Tension - The WINDING WEB
Tension
Nip - The NIP of the Pressure
Roll or Drum
Torque - The TORQUE from the
Center Drive or Torque Drum
Winding Principles verses
Material Characteristics
Low Modulus (Stretchy) Materials-
Tension is the dominant principle
High Modulus (Stiff) Materials-
Nip and Torque are the dominant
principles.
How much Tension should you use?
Web Tension Guidelines published in
AIMCAL’s Converting Quarterly
Page 58, Issue 2011, Quarter 3
Extensible Films- Web Tension is
Dominate Winding Principle

How To Determine
the Maximum amount of Tension
to Wind Film Webs at ????
Maximum Allowable Tension
–Empirical data has shown that a
tensile stress of 1.5% of the elastic
modulus, or Modulus of Elasticity,
can be applied without inducing
significant permanent stresses in
film webs.
Modulus of Elasticity
Some typical secant moduli are:
•Flexible PVC 350- 560 kg/cm2 (5-8 kpsi)
•LDPE 1,000-1,800 kg/cm2 (15-25 kpsi)
•LLDPE 2,000-2,800 kg/cm2 (29-40 kpsi)
•HDPE 5,600- 9,100 kg/cm2 (80-130 kpsi)
•BOPP 7,700- 24,000 kg/cm2 (110-350 kpsi)
•PET 14,000- 38,000 kg/cm2 (200-550 kpsi)
Maximum Allowable Tension
Example:
Maximum Tension of 50 micron (.05mm) LDPE
Assume a modulus of 1,400 kg/cm2 (LDPE)
1.5% of 1,400 is .015 x 1,400 or 21 kg/cm2
For a 1500mm wide x .05mm thick web
1500mm x .05mm x .21 kg/mm2 = 15 kg Max. Tension.

Try to keep web at or below this tension during

processing
Tension Principles of Winding
Taper Tension
–Reduce the tension smoothly as
the roll diameter increases
•0 - 50% taper, 25% common
–Taper Tension reduces roll
defects such as - Telescoping,
Buckling and Starring
NIP Principle of TNT Winding
Nip of Winding Rolls :
• Removes the boundary layer of air following
the Web.
• Adds Inwound Tension - The higher the nip,
the harder the rolls.
Challenge is to have sufficient nip to Wind
hard & straight rolls without winding in too
much inwound tension to prevent blocking
and deforming the web over caliper bands.
NIP Principle of TNT Winding
• Nip must be applied
where web enters the
winding roll.
• The winding roll’s &
lay-on roll’s weight
and web tension
should not affect the
Nip loading.
NIP Principle of TNT Winding
• Nip Load should be
tapered as roll winds to
prevent starring and
telescoping.
• However, larger winding
roll’s dia. drags more air
and produces a larger
footprint for Tapered
Loading Pressure with a
constant loading force.
Gap Winding
Air sometimes wants to be wound into the
winding roll of material to:
• Prevent blocking problems
• Prevent deforming the web that is
wound too tightly over gauge bands
Lay-on Roll should follow the Winding
Roll’s Surface with a Small Controlled
Gap – Directs the web squarely into the
winding roll.
 TORQUE Principle of TNT Winding

• Torque cinches the inner layers while winding

• Torque produces Web Tension when Center Winding
• Torque Independent from Web Tension when C/S Winding
TORQUE Principle of TNT Winding
Typically, the winding tension starts at
25-50% greater than the incoming web
tension and then this winding tension is
tapered as the roll builds in diameter to
a value at or even less than the
incoming web tension.
Basic types Winding Processes
–Center Winding
–Surface Winding
–Combination Center/Surface
Winding
EACH TYPE USES ONE OR
MORE OF THE T.N.T.
PRINCIPLES TO BUILD ROLL
HARDNESS
Center Type Winder

Tension & Nip

are Dominant
Winding
Principles
Center Winders
Gap Winding - Use web Tension only.
(Web tension provided by spindle torque)

Contact Winding - Use web Tension and Nip

To control roll hardness
Advantages - Can build softer rolls.
Quick indexing, fast cycle times.

Disadvantages - Limited maximum roll dia. due

to torque applied thru layers.
Higher probability of scrap during roll changes.
Center Winders
• Best for Winding Small Diameter Rolls
• Best for Winding Soft Rolls
i.e. Films with Gauge Bands
• Good Control of Inwound Tension
• Easily Provides Dual Direction
Winding
• Can Provide Adhesiveless Transfers
Turret Center Winders
Drum Surface Winders
Drum Surface Winders
Winding Elastic Materials -
Web Tension is dominant winding principle.
Winding Inelastic Materials -
Nip is dominant winding principle.
Advantage - Web Tension is not supplied from
torque applied thru the roll.
Disadvantage - Can not wind air into roll to
minimize gauge bands and roll blocking.
Drum Surface Winders
• Best for Winding Very Large Dia. Rolls
• Best for Winding Hard Rolls
i.e. Protective Films
• Best Utilization of Space and Horsepower
• Minimum Waste During Transfers
• Less Expensive
– Less Equipment
– Single and Smaller Winding Drive
 Drum Surface Winders
+ In-line slitting with little waste
+ Thread up is simple and accessible
+ Winding of Large Dia. Rolls of Non-Extensible webs
− Tension is not controlled through the wound layers
(tension is only known prior to the drum)
− Typically single direction winding only
− Requires tape or glue on core for auto. transfers
− No gap winding available
Drum Surface Winders
Center/Surface Type Winder
Web Tension
Independent
Winding Principle
from Winding
Torque
Center/Surface Winders
Can use all three TNT principles -
Tension, which is used for slitting and spreading,
controlled by Surface Drive.
Nip is controlled by the lay-on roll loading.
Torque from spindle drive controls roll hardness
independent from web Tension.
Advantages - Can wind with best control of inwound
tension and improve the ability to produce shippable
quality slit rolls off the production winder.
Disadvantages- More costly and complex.
Center/Surface Winders
• Best for winding w/ optimum roll quality
• Best for winding high slippery webs
• Best for slitting and winding to larger
rewind diameters
• Best for ability to significantly taper in-
wound tension without affecting the width
of extensible webs
• Able to supply in-wound tension without
stretching the web over caliper bands
Tech Tip- When to Use Center/Surface
Winders

For Information on how to get a copy of any of my Tech Tips or

Technical Papers - Please give me your card with Email address
Guide for Selecting the Best Winding
Process for Your Products
Suggested Winding Process

1 – Center Winding Process

2 – Surface Winding Process

3 – Combination Center / Surface Winding Process

Material Characteristics Suggested Winding Process

Thin Webs processed at High Speeds 1

Thick Webs wound to Large Diameters 2, 3

Extensible “stretchy” Webs - Large Dia. 2

Non-Extensible Webs - Thin, Small Dia. 1

High Coefficient “Sticky” Materials 1

Low Coefficient “Slippery” Materials 3

Inline Slitting in Multiple Webs 3

Guide helps to determine the best type of
winding process. Yet determining the
proportional amount of the T.N.T. Winding
Principles for different types of web
materials
Is still considered an ART
Setting And Programming Of Tension, Nip &
Torque Will Vary Depending On:
• Type & Design of Winder
• Type of Web Material
• Width of Rolls Being Wound
• Speed of Winding Operation
Different Web Products and Different
Applications Dictate Desired Roll Hardness
HARDNESS PROFILE MUST BE
REPRODUCED CONSISTENTLY
Roll Hardness Measuring Devices Need To
Be Available To Winder Operators
• RHOMETER & SCHMIDT HAMMER -
Measures Hardness Across Outer Surface
• PAROtester & TAPIO RQP (Roll Quality Profiler)-
Measures Hardness Across Outer Surface
• SMITH NEEDLE - Measures Hardness from Core
to Full Roll
• RDF Curve (Microprocessor Control System) -
Measures Roll Density During Winding
RHOMETER
SCHMIDT HAMMER
PAROtester
PAROtester
TAPIO RQP (Roll Quality Profiler)
TAPIO RQP (Roll Quality Profiler)
SMITH NEEDLE
AccuWind Roll Density Curves
For Contact Information on these
Roll Hardness Measuring Devices:
• RHOMETER
• SCHMIDT HAMMER
• PAROtester
• TAPIO RQP
• SMITH NEEDLE
Please give me your card with Email address
Guidelines for Selecting the Best Winding
Process for Your Products

Questions
????
Thank You!
R. Duane Smith
Product Manager – Specialty Winding
Davis-Standard, LLC

smithd@bc-egan.com