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Doubled Throughput and Higher Quality for Converters E-mail
Friday, 16 March 2007

Mapleroc Industries RollRazor (tm)New Machine Resizes Paper on the Original Roll in Just 3 Minutes

MapleRoc Industries has introduced the first production alternative to a slitter/rewinder to serve the paper industry in 50 years.

Using a highly engineered blade that generates virtually no heat, the RollRazor cuts original “from the manufacturer” rolls from the outer diameter through the core in one pass, creating a press-ready roll in only 3 minutes. Rolls that are re-sized using the RollRazor retain all the characteristics of the mill wound roll—which greatly reduces registration problems, web breaks and other costs inherent in rolls resized using traditional slitters/rewinders.

Increases throughput up to 200%

Fast and efficient resizing has been the roll converter’s Holy Grail. Unwinding and rewinding rolls is simply a long process. To be sure, when core and/or diameter changes are required, rewinders make sense. But running rolls through a rewinder to change widths alone doesn’t.

“This technology is very compelling in terms of the numbers, speed and efficiencies. I believe we can almost double our throughput with our current labor and fixed costs,” says Ralph Carpenter, founder of Northeast Paper Services, who has added RollRazor to his operation. “The single-cut approach is great, especially when you’re working on water damaged rolls and looking to trim two inches off the ends; this technology blows away the winders.”

Retains Original Mill Wind Quality

An inherent pitfall of rewinding technology is the loss of original mill winding tension in a roll.

“You’re at the mercy of the winding operator at any given day on a given piece of equipment to get a good rewind on the roll so it runs smoothly on-press”, says Don Mercer, Senior Technical Support Manager at Irving Paper. “It is critical to maintain an even tension throughout a roll of paper, so that when it is on press you keep the printing register. The press operators are constantly trying to maintain even tension throughout the roll as it advances through the printing presses. If there are tension upsets in the roll, odds are that you will have register problems or, in the worst case, web breaks.”

Because RollRazor resizes original, straight-from-the-mill rolls, it eliminates the quality problems inherent with resizing using a slitter/rewinder. In fact, press-room performance issues with rolls resized on the RollRazor are less than 1% as compared with the industry average of more than 3%. As any printer will attest, that 2% plus performance improvement looms large when jobs are moving through the plant.

Flexibility

By moving the bulk of their resizing work to the RollRazor, converters can dramatically increase their operation’s throughput—in most cases by 200% to 300%. Their slitter/rewinders can then be dedicated to doing what they do best, taking on jobs that require diameter and/or core changes.

RollRazor can resize rolls from 10" to 132" wide and 30" to 60" diameter, providing greater inventory utilization, less trim waste, and the ability to meet customer demand—even on short notice.

The RollRazor is designed for production plants that are converting 800 tons or more per month. Prospective customers can see an online demo at www.rollrazor.com.
Last Updated ( Friday, 16 March 2007 )
 
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