Double E recently helped one of the world’s largest commercial printing companies meet a new slitting requirement for one of its clients. The printer uses a Xeikon digital web press for special projects that run an 80 Ib., 20″ wide web material at a speed of 40 feet per minute. The press did not have any slitting capabilities, but the new project required the material to be slit into two 9.5″ sections. This production technique would be more efficient and cost effective, but they were having problems making the center cut. Double E recommended a shear center cut system to solve the problem.

Double E engineered a custom stand-alone center cut station that would fit between the printing and rewind sections of the Xeikon digital press. Since there was a very small space to work in (only 20″ in length), this proved to be quite a challenge. However, Double E was able to create a completely customized stand that was compact enough to fit between the machine’s two sections, while also matching the web’s height so that there would be no need to make adjustments to the Xeikon digital press. This station featured a Mario Cotta “Tiny” shear cut pneumatic holder to provide a high quality cut, with the added benefit of a long blade life. Integrating the new slitting station was not difficult for the customer – an air line for the pneumatic holder, power for the Siemens motor, and a speed reference signal that would regulate the speed were the only connections needed.

The customer is pleased with the results of the slitting station. The stand fit perfectly within their Xeikon machine and the basic plug-and-play delivery minimized down time. Once all of power, air, and signal lines were connected, the slitter worked with great efficiency to provide a high quality cut to the web material. When the slitter wasn’t needed, the web would simply run smoothly through the station without disrupting the line speed and tension. The customer also ordered a duplicate slitting station for the same type of machine at one of their other facilities.

Center Cut Slitting Station

One of the largest pressure-sensitive roll label suppliers in the country approached Double E with concerns about the slitting section on one of their production lines. They were not happy with the setup of their current holders and the quality of the cut the slitters were producing. The customer uses a doctor machine for line inspections that utilizes a series of Mario Cotta “Gold” series knife holders. They were so impressed with the ease of use and quality of the holders that they asked Double E to develop a similar system for their production line machine.

Double E went to work designing a slitting system that would easily bolt onto the existing machine. All twenty of the old holders were replaced with new “Gold” series holders attached to a new support beam. This much more robust support beam features a rack and pinion rail system allowing the operator to adjust the knife position more easily and accurately.

On the anvil side, the customer required a digital readout to position their anvils. Unfortunately, due to the excessive adhesive buildup, they needed to be able to move the digital readout system out of the way to clean the anvils. To alleviate this problem, Double E engineered a digital readout system on a linear rail that is pneumatically actuated so that the machine operator could move the system out of the way during maintenance and cleaning. Installation of the new system went smoothly once all of the components were delivered to the customer. The complete modification of the machine including disassembly of the old parts and fitting the new knife holder system and digital readout system took less than a business day.

Once the knives were adjusted and calibrated, the production line was ready to run at full capacity. The customer has since expressed how pleased they are with the new modifications to their slitting machine. The ease of use along with the added safety has given the customer true piece of mind knowing that their product is at the highest possible quality and their operators are safe during routine maintenance.

Recently the Double E Company worked with a producer of large-format digital graphics who specializes in large scale banners and billboards. The company had a situation where they needed a way to manufacture a welded pocket seam in the film material before it went to print. They were trying to unwind a 5″ film strip, fold it in half and weld the edges together. The process they were using proved unsuccessful so they asked Double E to engineer a small tension controlled unwind station that could be easily mounted to the production line.

Double E’s solution featured a narrow web device consisting of a SR-2000 strip chuck mounted on a safety chuck body and regulated with a Re Eleflex electromagnetic powder brake. This narrow web station combined with the Re CF.85 load cell, tension roller and integrated tension control system with a T.1 controller provided the solution for regulating the tension during the unwind process. The customer was now able to provide a consistent method for welding the pocket seam.

The success of the initial narrow web station prompted the customer to order four more units for each of the production lines.

For more information about the CBA-1000 Narrow Web Unwind / Rewind Stations, please contact Double E Company.

CBA-1000 Narrow Web Station

Re Tension Roller & Load Cell

Integrated Tension Control System with a T.1 Controller

Double E often has direct replacements to make upgrading from other manufacturer’s chucks simple, but even when a retrofit is more challenging, Double E applies its experience and expertise to solve problems for its customers. As an example, Double E recently worked with a flexible packaging converter that needed to replace safety chucks because parts were no longer available. Since the bearing housings on the existing safety chucks were integrated into the machine frame, the customer was having difficulties finding a direct replacement.

Double E engineers designed new safety chucks to fit the customer’s machine by taking measurements from the existing spindles. They planned carefully for a tricky installation then machinists manufactured two pairs of custom modern chucks with sliding faceplates to replace the old ones. Installing the new chucks would be challenging because of their position on the machine, but the Double E engineers took this into consideration. They created special mounts that would allow seamless integration. With a few minor adjustments on-site, the safety chucks fit properly into the machine, and the safety chuck upgrade was complete.

Double E also provided new 6″ strip shafts to be used with the safety chucks, and DF-2000 core chucks (on the unwind) to complete the project. Double E was able to extend the life of the customer’s dependable turret winder machine and today the product line is running at full capacity. The production manager expressed his appreciation for how dedicated and detailed oriented Double E was throughout the project.

This project demonstrates Double E’s ability to help its customers by engineering custom solutions.

The Double E Company has worked closely with many customers over the years regarding solutions to slitting dilemmas. Recently a customer in the tissue industry came to Double E looking to upgrade from the tried and true Mario Cotter PPS model to a newer knife holder. The customer was able to get many years of service from the PPS but dust was starting to build up due to the excessive cant angle on the holders and worn out multi-groove anvils. Another problem was that the holders were located inside their Fabio Prerini Slitter/Rewinder machine with very limited access and they needed a holder that provided easier blade changes. Double E introduced the customer to the “Gold” series knife holder by Mario Cotta.

The production manager agreed to purchase a Gold series holder for a brief trial period. Since the customer was upgrading to a newer Mario Cotta device, the drop-in replacement was effortless. The production manager was intrigued by the knife holder’s mounting flexibility and once the production line started using the device, he soon realized the benefits of the error-free cant angle adjustment and the blade guard safety feature. The line operators found it easier than ever before to replace blades…because the simple cartridge system allows them to pull one out and replace it without tools.

The production manager was so pleased with the “Gold” series knife holder that he immediately outfitted his entire production line with “Gold” series knife holders and multi-groove anvils. These Mario Cotta holders save time, yield unparalleled cut quality, and alleviate the dust issue. He also has the peace-of-mind of knowing that parts availability and product support are never a problem with Mario Cotta.

Mario Cotta "Gold" Series holder shown on trial next to the older PPS holder.

For more information, please contact Double E Company, the exclusive distributor of Mario Cotta slitting equipment in North America.

Double E’s DF-2000 core chuck is used by the large majority of corrugators throughout the USA, and in fact, all over the world. It has been the industry standard for over three decades.

Recently, some corrugating plants have seen a degradation in core quality that has caused the cores to fail, even in normal operating conditions. To overcome the inherent weakness in these cheaper cores, Double E recommends its EHDL (Extra Heavy Duty Long) DF-2000 core chuck. It is a larger and beefier version of the standard chuck, but offers a contact patch area 40% larger. This difference allows the chuck to spread the torque over a greater surface area of the core to ensure normal processing.

An increasingly common story in the corrugating industry is exemplified by one Double E customer in Massachusetts. The maintenance manager at this particular plant was suddenly plagued by core tear-out problems after years of care-free operation. Slipping was making it impossible to run rolls to the last wrap, forcing slower machine speeds, and even leading to reduced board quality. The plant was losing money on wasted material and on wasted time. Thinking the problem was being caused by the Double E DF-2000 chucks that were installed on all of his machines, he called Double E to complain.

Double E worked with the customer to determine that the chucks were functioning properly. They had been working for over six years and were still in perfect mechanical condition. They hadn’t changed, but something was wrong. Double E engineers tested the cores being used at the plant and found that they were thinner than usual and that they frayed easily. As it turned out, the core supplier had changed their process to reduce costs. The cores were thinner and did not meet the specifications necessary for normal processing. The core manufacturer wasn’t going back to the old way, and more and more suppliers are following suit.

This corrugator, like many others, had to deal with this new reality of inferior core quality. Double E proposed its EHDL chuck. Its larger gripping jaws grip more of the core to minimize the chance of slipping. The customer purchased a pair of the larger chucks as a test, and saw the problem end immediately. They subsequently upgraded all of their roll stands, and have now returned to the care-free operation that they enjoyed previously.

If you’re having problems with core tear out, you are not alone. Double E’s Extra Heavy Duty Long DF-2000 core chuck can help. Please contact the Double E Company for more information.

The Double E Company is pleased to announce the new nip/pull roll stations that you can use to set tension zones or master line speeds. These stations easily synchronize with any section of the production line to help continue production at an even pace.

• Use of induction motors or servo motors
• Siemens motor drivers and controls
• Custom touch screen programming
• Adjustable nip pressure and options on nip roll coverings
• Accommodate a large range of web widths and materials
• Integration with your existing machine controls

Learn more

Recently the Double E Company worked with a customer that converts wrapping paper with various thicknesses. The production manager was having cut quality problems with the company’s old OEM knife holders and parts availability problems with replacement holders that the company had purchased not too long ago. He was frustrated with being forced to upgrade to new holders, but since he was being forced to do it anyway, he decided to test a better solution. Double E introduced the customer to the “Gold” series knife holder by Mario Cotta.

The production manager agreed to purchase one holder for a 30-day test. It was easy to mount the new holder on the slitting machine with a simple bolt on adapter bracket, and the line was up and running in no time. He was intrigued by the knife holder’s mounting flexibility and once the production line started using the device, he soon realized the benefits of the error-free cant angle adjustment and the blade guard safety feature. None of his previous holders had these types of standard features. Operators also found it easier than ever before to replace blades…because the simple cartridge system allows them to pull one out and replace it without tools.

The customer was so pleased with the “Gold” series knife holder that he immediately ordered three more. Now the production manager has absolute confidence in his production line. The Mario Cotta holders save time, yield unparalleled cut quality, and provide a higher level of safety for his personnel. He also has the peace-of-mind of knowing that parts availability and product support are never a problem with Mario Cotta.

For more information, please contact Double E Company, the exclusive distributor of Mario Cotta slitting equipment in North America.

Mario Cotta's "GOLD" Series Holder installed on customer's slitting machine.

Double E continues to increase its sales and support network around the world. The company is pleased to introduce Bryan Moss to customers in Alabama, Arkansas, Louisiana, and Mississippi. Bryan is based in Birmingham, AL, and can be reached using this information:

Phone: 205-955-2488
email: bmoss@doubleeusa.com

ReVision video inspection systems have allowed one Double E customer to minimize wasted material due to imperfect printing, and to end maintenance headaches caused by a previous inspection camera.

The Double E Company recently worked with a customer that produces a variety of flexible packaging materials employed in the food, medical, industrial and chemical industries. This customer runs six different printing lines in its 70,000 square foot facility two of which are 8-color central impression type flexographic presses. These presses produce high quality process work at very high speeds. The customer was in dire need of a reliable, simple way to check print quality during the run, since the speed of the line makes checking manually virtually impossible.

Both of these flexographic presses had previously installed web vision systems. One used a five-year-old camera system manufactured by a company that has since gone out of business. Obtaining parts and support for this product was out of the question. The other flexographic press used a different web vision system that was complicated to run and required frequent, expensive repairs. The customer needed a simple, reliable web inspection system that would enable them to check print quality during the run.

Double E’s solution to the customer’s need for a simple, reliable web inspection system was the Re MH100 Web Vision System. The MH100 is particularly adapted for flexographic and rotogravure printing machines utilizing a CMOS sensor to obtain unmatched color accuracy and image quality. The easy split screen function allows the operators to make quick comparisons with excellent image quality. The automatic scanning also gives the operators the ability to regulate between split vertical, split horizontal, split vertical and horizontal or full screen. This gives the customer the ability to print at high speed and make adjustments quickly which reduces costly material waste.

Today this producer of flexible packaging materials is running at full capacity with minimal down time thanks in part to the Re MH100 Web Vision Systems. Since these systems were installed, both lines have been able to produce stunning products at full speed with very little material waste.

For more information about ReVision, please click here:

http://www.doubleeusa.com/web-inspection/web-inspection.htm