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Optimised Paper Handling & Logistics 7 - WAN

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1. e Store the paper in the pressroom for a few days before use if a there is a significant difference in temperature and humidity between the pressroom and paper storage area or b if paper is delivered directly to the pressroom from the paper supplier e Conditioning time depends on the temperature difference between transport or warehouse environment and the pressroom the conductivity of the paper and the size of the stack roll diameter or volume of sheets on a pallet Conditioning time for rolls also depends upon their diameter because they condition from the edges inwards See conditioning chart Module 3 OPTIMISED PAPER HANDLING amp LOGISTICS 7 At the Printer Paper onto Press 3 Paper Rolls Keep the protective wrapping on as long as possible to minimise risk of damage and the negative effects of atmospheric humidity and dynamic roll expansion The open time of prepared rolls is determined by the grade of paper and the ambient pressroom RH In extremely cold winter conditions the outer layers of paper warm up relatively quickly but the paper near to the core splice area contact point can take two weeks to obtain an ideal minimum splicing temperature of 15 C 59 F Below this temperature there is a high risk of splice failure Some printers place heaters in the roll core to warm up the adjacent paper to a temperature high enough for splicing adhesives to work others use liquid glue over a large area on frozen coated paper
2. 7 At the Printer Paper onto Press Roll Cores an Integrated Renewable Component Cores should be considered as an integrated renewable component relating to both the paper machine winder and the printing press splicer in order to achieve high efficiency and reduce waste across the delivery and process chain The function of the core is to support the paper roll It must be of sufficient strength and stiffness to prevent crushing in normal handling while during winding and printing it must transmit torque and avoid vibration and delamination Most offset splicers now use core braking and acceleration making the quality of the core critical to the transfer of torque Splicers use shafts or chucks to support the roll by the core and firmly lock it without slippage including during emergency stops Shafts run through the core and are either mechanically or pneumatically expanded to provide good adhesion along the length of the core but they cannot be used with damaged cores Chucks penetrate only the ends of cores and therefore these must be of adequate quality and condition to withstand braking torque Source Sonoco Alcore Core Specifications Normally it is the paper suppliers responsibility to ensure that the cores on which paper is supplied conform to the printer s requirements These are determined by the web width roll diameter and weight and production speed Appropriate core properties are important to run the winder a
3. Printers who do not have roll handling clamp trucks require their rolls to be supplied on pallets that can be handled manually and with conventional forklift equipment Use forklifts with angled clamps to better handle standing rolls that otherwise may risk being deformed on the bottom that can lead to unwinding problems Source Mabeg 1 The paper web coming from an unwinder runs through an infeed into the cutting unit 2 Ashearing system ensures a clean cut and precise angles The web tension is controlled automatically 3 Adecurler can be activated to achieve sheet flatness if necessary 4 Running out of the crosscutter the sheets are overlapped in the stream feeding device and the shingled sheets conveyed on the transporttable of the press s sheetfeeder The sheeter can be moved aside when conventional pile feeding is required Roll loaded on to an electric truck equipped with angled forks Source Mabeg Crosscutter Roll Sheeting Systems Source Beiliomatic Roll to sheet systems are also for used in different converting applications to convert rolls of paper carton and foil into sheets that are delivered into a stacker to create a sheet pile Some systems allow preprinted rolls to be processed in register and without leaving marks Crosscutters are used by paper wholesalers packaging suppliers and printers Use best practice techniques for roll handling described earlier in this Module and also in Modules
4. Local papermaking weaknesses that may cause web breaks include poor mill splices creases and hairline cuts that might not resist the tensions applied to the web Paper and Roll Characteristics Paper is primarily composed of natural cellular materials which by their nature are locally variable and do not react to a given stress in the same way There will always be some variation in tension profile in all papers from all suppliers It is normal that there are variations of tension 1 across the width of the papermaking machine consequently with a variation from roll to roll 2 between the surface and core layers and 3 at mill splices near cores Modern paper mill winders run at speeds up to 50 m s 8000 fpm on webs over 9 m 30 wide To obtain a good and even winding it is important to have even profiles of moisture hardness and tension Mill join splices are made after a web break or to make fillings joining two tambour reels to fit customer diameters Mill joins should be coloured to allow photocell detection and physical separation and should not be closer than 70 mm 2 75 to the core to avoid any disturbance to the splice cycle and tension To minimise roll to roll tension variations some printers organise their internal paper storage to print from rolls from the same tambour position This practice is claimed to provide lower tension variations between rolls during splicing and running contributing to waste reduction and redu
5. Pull individual wraps from the roll inspecting the edges and belly for damage Roll surface must be free from impression marks made by stones nails wooden parts If OK prepare the splice If further stripping is needed tear the top layers by hand before introducing the stripping tool Once the roll is damage free prepare the splice Experience shows that some edge and side damage does not always require stripping to the bottom of the damage This can often be treated by carefully cutting out with a sharp knife and or sanding of the area The press operator should be informed of the problem so that he can slow down the press and nurse the damaged web through the press Applying a lubricant to damaged area may assist passage through the press Failure to identify end damage may result in a web break during production Risks of accidental damage to the white paper are increased Over zealous use of the stripper will result in unnecessary waste Frequently more layers are stripped off than are really necessary It is important to remember that much more paper can be saved atthe top of a reel compared with near the core e g 5 mm 0 25 at the top of a reel is equivalent to 5 cm 2 at the core STRIPPING WASTE CALCULATION CHART Stripping waste as of total paper on roll Dynamic roll expansion if wrapper removed too early Source WOCG icmPrint Depth of Roll Roll
6. A side effect of cold paper is that the inking system cools down and creates flow problems x Preparing splice patterns of several rolls in advance could increase risk of the splice pattern breaking open as unwrapped rolls take up moisture quickly in the outer spires layers This increases the risk of creasing and expansion that can burst the splice pattern Keep the protective roll wrapping on as long as possible x Taking the end shields off too early can cause roll edges to dry out or absorb moisture resulting in a visibly skewed profile as the web leaves the roll Reduce heatset web static by remoistening the paper after the chill rolls with a mixture of water silicone and liquid fabric softener Sheetfed Paper Issues Dimension variations Paper fibres will either absorb or exude moisture depending on RH Causing them to swell or to shrink particularly in the cross direction of the paper rather than in the machine direction A 10 change in RH causes paper to grow 0 1 to 0 2 across the width which will cause printing mis register Humidity and curling Curling is closely connected to fluctuations in humidity that cause the paper fibres to expand and shrink in the cross direction If paper is moistened on one side the fibres expand in one direction causing the paper to curl toward the dry side As soon as a balance in humidity within the paper structure has been restored the effect is cancelled out Stack humidity and te
7. Layers glued together Glue spray inbetween layers Bad cutting Wipe dust down with smooth tissue or and roll end causes breaks Remove hard hotmelt spots velvet Clean roll end with slightly oiled cotton cleaning with knife or grind them with sand paper Slab off large cloth Do not use water or water spray because paper areas becomes wavy and changes dimension and its layers may become glued together after drying x The Splice Thorn device a pin inserted into the damaged core and spread hydraulically to restore the circular shape of the core to restore crushed cores to their original shape is now rarely used as it does not conform to high quality production Out of round Some of these rolls may be unwound but Glued roll ends Sand down the affected area using production speed may be affected However the high fine grain emery paper Slab off if the area is large Cut vibrations from running out of round rolls may make off a piece for the defect documentation and note roll splicing very difficult or even impossible Change to a number roll from a different batch Burst flagging Nail the area between the first paper Wrinkles pleats calender cuts Slab down a part of layer and core twice each end Nails should be placed the diameter After second break reject the roll from opposite each other Rolls with burst that have broken press and change to a roll from a different batch or twice should be rejected from press In
8. Paper onto Press Multi Function Splicing Tape These tapes combine different features for a simpler and more reliable splice performance e Easy to use for operators e Reliable high quality tape with perfect wetting on most paper grades Prevention of air pockets and premature opening during roll acceleration Easy opening of the splitting strip and high initial tack at the moment of splice to web contact e Shear resistant bonding of the top sheet even for rolls prepared in advance and throughout the press e Reliable splice recognition when using splicing tapes with integrated detection Contact adhesive Splicing tapes use PSA pressure sensitive adhesive with high tack for three functions 1 Secure attachment of the top spire of new paper roll during storage transport and acceleration in the paster 2 Optimum contact between expiring and new web atthe moment of splice The bond intensity mE P Multi function splicing tape Is influenced by the pressure and condition of the contact roller or brush in the splicer 1 Splitting strip 2 High tack contact adhesive 3 Integrated detection feature 3 Heat resistant adhesive for high temperatures of heatset press dryer Source tessa amp Follow the manufacturer s settings and maintenance Splitting strip Provides secure closure of the incoming paper roll during storage transport and acceleration in the splicer During the splice process the strip precisely opens
9. adhesive tape The web is ready to be printed OPTIMISED PAPER HANDLING amp LOGISTICS Automatic Roll Changing amp Splicing An automatic splicer converts rolls into a continuous web by splicing from roll to roll at full press speed and also assists in loading Key qualities of the splice and roll change process are e Maintain tension and lateral position in relation to press infeed web guide e Minimise web breaks splice failures press downtime and waste e Minimise paper running waste e Measure running length There are two technologies Flying splicers sometimes called pasters or match speed and zero speed splicers The main difference between them is that a zero speed splice occurs when the web is stationery but the press runs at full speed while a flying splice occurs at the match speed of the running press There are many variations to these basic designs and this guide must be read in association with the operator s manual s for the machines in your plant Butt splicing is complicated to automate on zero speed splicers and for this reason the splice tail needs to be short and secured To minimise risk some inkjet presses have splice detectors to liftthe printing heads from the web Technology Options Shafts or Chucks Shafts run all of the way through the core and are either mechanically or pneumatically expanded They provide good adhesion along the length of the core but cannot be used with damaged cores They
10. 4 and 5 OPTIMISED PAPER HANDLING amp LOGISTICS Problem Feeder Misses or Doubles Uneven Forwarding Stains on Sheets Conveyor Cocking Jamming Front Register Variation Push Side Guide Variation Pull Side Guide Variation Nicked or Torn Gripper Edges Sheets Pull Out of Gripper and Stick to Blanket Wrinkles or Creases Poor Fit at Tail Edge Poor Multi Colour Fit 7 At the Printer Paper onto Press Causes Misses Paper pile too high Doubles Paper pile too low Too much separation air blast Suckers malfunction Sheets are stuck together Sheets not separating burred edges Poor sheet separation and feeding Static in paper Too much or too little air under top sheet Dirty rotary valve Air blast nozzles incorrectly aligned Compressor overheated or over oiled Single sheet feeder forwarding wheels Forwarding wheels in poor condition Transfer tapes in poor condition Rust or moisture on feedboard Curling of front edges and sheets fails to enter side guide Static build up in paper or feed tapes Not enough clearance under hold down springs or fingers Too much clearance under hold down Tail end wheels too far back or forward Sheet gripper edge or tail not straight or sheets vary in length from to back Sheets slip in impression cylinder grippers Poor synchronisation with grippers Incorrect timing of overfeed roll Uneven paper trim or out of square Pusher plate not parallel to edge of sh
11. EFFICIENCY 6 Web Breaks 7 Splice Faults and Web Breaks 8 Roll Changing amp Splicing Devices 13 Roll Cores 14 Splicing Tapes and Tabs 16 Web Tension a Key to Efficiency 17 Preparing the Roll for Splicing 18 Roll to Web Processing Steps 24 Flying Splicer Straight Patterns 25 Splice Tails 26 Zero Speed Splicing 28 Core Troubleshootin A IMPORTANT SAFETY NOTICE A general guide cannot take into account the specificity of all products procedures laws and regulations We therefore recommend that this guide be used only as a complement to 30 Paper Roll Repairs information from suppliers whose safety operating and maintenance procedures along with applicable local legal regulations always take precedence over this guide Always check 32 SHEETS amp PALLETISED PAPER machine is in its specified safe position before working on any component e g with compressed 32 Paper Handling for Sheetfed Presses air electrical power and gas disconnected Only trained maintenance personnel adhering to 37 Sheetfed Press Feeder safety regulations should perform maintenance work 33 Roll to Sheet Feeder Jb Sheet Paper Problems Best Practice A Safety 36 Climate and Edge Problems 37 Minimise Climate and Paper Problems 2 l Nam xX Poor Practice Environmental amp Economic Impact 37 Static Electricity in Paper 38 SEPARATE AND RECYCLE WASTE 29 Troubl
12. When all issues on the check list have been clarified practical realisation for initial loading operations should be carried out locally in the presence of a competent representative of each of the companies involved Frequent problems are The cargo has not yet been delivered in full mm The planned stowage locations do not comply with the requirements The cargo hold is not swept properly Cargo residues are present in the hatch frame Large amounts of water fall into the hatch when the cargo hatches are opened The hatches cannot be closed quickly enough when it starts to rain Work continues in rain or snow contrary to agreement The cargo is not stowed properly Fork lift drivers are inexperienced in handling the cargo Cargo handling equipment is unsuitable for the product The cargo is over stowed with other cargo contrary to agreement Contact partners are unavailable or do not have the necessary competence If the conditions deviate considerably from those agreed then loading should be stopped until clarification is provided Cargo Conditions for Paper Inspect vessel before loading begins Cargo deck must be dry clean and watertight Cargo is correctly stowed and secured Minimize condensation by using moisture absorbing materials and ensure proper ventilation and drainage Correct handling equipment and techniques for unloading loading Observe the weather conditions during loadin
13. after pasting contact from a defined strip width and specified opening force The splitting strip is like a breaking point independent of the tape s width positioned 2 mm from the tape s edge for a reliable lifting of the splice A lower opening force is recommended for belt driven splicers and low quality paper Integrated detection Reliable splice detection for the correct timing of the contact roller and t the knife to cut the expiring web can come from either a mechanical mark on the splicer s axis or automatically using an optical or inductive sensor Automatic splice detection reduces the number of mistakes due to wrong tab positioning the splice will be detected directly on the tape s position It requires either detection tabs or splicing tapes with integrated detection e A black backing for optical sensors in the splicer e Aluminium backing for inductive sensors in the splicer and postpress to remove printed copies with tape Roll ready for splicing Source tessa Ensure the correct splice tail length when changing from detection tabs to splicing tapes with integrated detection Request settings from the splicer supplier Temperature and Humidity for Tapes Repulpable adhesives offer very good wetting on paper but also react with the environment and substrate temperature and humidity Adhesive properties are influenced by temperature and humidity different adhesive formulations are available to deal with some
14. and regulations We therefore recommend that this guide be used only as a complement to information from suppliers whose safety operating and maintenance procedures along with applicable local legal regulations always take precedence over this guide Always check machine is in its specified safe position before working on any component e g with compressed air electrical power and gas disconnected Only trained maintenance personnel adhering to safety regulations should perform maintenance work Best Practice A Safety 2 x Poor Practice Environmental amp Economic Impact OPTIMISED PAPER HANDLING amp LOGISTICS 3 Warehouse amp Paper Store 3 Warehouse IMPORTANT SAFETY NOTICE A general guide cannot take into account the specificity of all products procedures laws and regulations We therefore recommend that this guide be used only as a complement to information from suppliers whose safety operating and maintenance procedures along with applicable local legal regulations always take precedence over this guide Always check machine is in its specified safe position before working on any component e g with compressed air electrical power and gas disconnected Only trained maintenance personnel adhering to safety regulations should perform maintenance work A Safety 2 Environmental amp Economic Impact OPTIMISED PAPER HANDLING amp LOGISTICS 6 Transport 6 Transport Containe
15. and the pressroom Paper is a non conductive material that can accumulate static electricity leading to feeding problems when individual sheets resist separation at the feeder head causing double sheeting and interfering with forwarding and timing into the head stops A static charge also attracts airborne contaminants onto the paper leading to hickeys or print voids Paper coating is an insulator that increases the risk of static compared to uncoated paper Gloss coated papers with large sheet size have the greatest risk because their smooth surface offers a large contact area with low weight Causes of static 1 Low air humidity aggravates static charge particularly below 35 RH Cold winter temperatures and high altitudes tend to lead to dryer conditions and static build up 2 Low paper moisture cold paper is less conductive and more prone to static build up than warmer paper acclimatised to recommended pressroom temperature 3 Incorrectly earthed equipment increases static charges The potential for static build up also increases with the contact area and pressure between paper and other surfaces and with heat static electricity in paper can be managed through a combination of e Effective earthing of machinery ionization and minimised heat for drying e Checking that air blower filters and heads are clean with adequate air pressure and distribution to ensure optimum sheet separation e Anti static or silicone sprays
16. identify the best recycling options e Regularly share recycling results with staff Separate Waste Paper and Board There are many different grades and prices for recycled papers Separate them by grade and into printed and unprinted types To achieve the best value for the recovered paper in the recycling chain papers should be sorted into the highest grades possible Sorting requires good internal co operation and success factors include the effective separation of incompatible materials and contamination control e White waste no ink coating or glue from roll stripping at splice preparation at web up and core waste has a significantly higher value than printed waste e Separate printed waste and bale it by grade to maximise its value Keep separate coated and varnished waste and jobs with very high background tint ink coverage e g directories e Brown roll and sheet wrapping can be reused to separate layers of printed product end caps can be reused to cap pallets of outgoing deliveries any excess can be shredded and sent to Collected waste paper for recycled pulp production a paper mill for recycling Source UPM e Cores can be shredded and either recycled or incinerated for energy e Office paper has a comparatively high value for recycling into other products treat used office paper as a separate recycling grade e Paper cartons from suppliers can be reused for packaging printed material or recycled in a si
17. increase conductivity and minimise excessive friction contact with paper transport components feedboard transport tapes wheels e Adequate pressroom moisture level increases conductivity helping dissipate static charge Recommended humidification source Sappi is 45 596 RH at 22 C 72 F 4 for North America and 52 5 RH at 21 C 70 F for Europe Moisturising systems help create optimal conditions in storage and pressrooms GUIDE NH 0 ADATE OTING ED OFFSET PRESS Guide to Troubleshooting of Sheetfed Press Printing Industries of America To check static take about 30 sheets from the top of the pile and then slowly slide the next sheet across the surface without lifting it If significant resistance is felt then a static charge is present causing a material attraction wa Cause amp Effects of a p l Static Electricity in Paper Problem cal cl The paper has developed a static electric g an abnormal cription dedi ii ae g Static electricity is defined as a non moving ni ionflowi de guide ve in simple terms electricity at re 2 Static z ctricity joment it sparks a scharge and for tatn instant it s shock Se anes s the E s the ually dn youre edt bees deerenninnne aby Oy ele atoms which in tur compos zu n 5 wed ns which mi ron movi utrality bec electro n ato atom to balance any aj applie um aot arges s ireehure cond
18. of these variations Newer generation tapes have an improved shelf life and a climate resistant adhesive to provide high stable tack under different environment conditions such as high humidity or low temperature of the paper rolls or pressroom Select tape type in relation to ambient temperature and humidity in your plant Consult tape supplier Store tape in its original packaging at a temperature between 10 40 C 50 104 F with 40 65 RH and away from direct UV exposure Respect the specified tape shelf life as adhesive qualities deteriorate over time Leave protective liner on tape as long as possible Cold conditions Store the tape in the original packaging at ambient pressroom temperature at least one day before use Special tapes are available High humidity conditions Keep the tape cool in a refrigerator except when being used to prepare a splice Special tapes are available OPTIMISED PAPER HANDLING amp LOGISTICS HAHHA t ttt ttt TELELETIT Source WOCG icmPrint Press speed Web tension Variation in the web tension profile is normal during different running states Source WOCG icmPrint Web Tension Key to Efficiency Optimum web tension is crucial for colour quality and high productivity Tension variations come from a paper b press line and c poor working practices Web break risk increases either when tension variations become excessive and or there are local area weaknesses in the web
19. ote ty al AANASAmATATATADAST A Apply glue to securely hold down the tail during its journey through the press and folder The effective tail length is determined by the type of splice pattern WOCG icmPrint Correct knife cut and short tail length Knife bounce or too high web tension mm LLLI Source WOCG icmPrint New roll too slow or knife misalignment Incorrect speed match OPTIMISED PAPER HANDLING amp LOGISTICS A Side view of preparation head B Trim off the excess web and apply the splicing tape C Transfer to nip roller D Close splice head and rotate nip roller in web direction until taut Source WOCG icmPrint 7 At the Printer Paper onto Press Zero Speed Rolling Nip Design Type A Open appropriate preparation bar Pull enough paper from new roll to reach past the preparation head and apply holding brake Place the web against the prep bar where the vacuum will hold it in place Align the edge ofthe web with the running roll Make sure web is square and uniformly tensioned B Trim off the excess web Use a sharp knife using the prep bar edge as a guide Apply the splicing tape across the full width of the web 2 mm from the paper edges on all three sides Do not allow tape to overhang edges Optimum adhesion requires pressure to be applied across the total width and length of the tape after positioning Trim off corners and leading edges to help allow for any small misalignment of web
20. the roll in the middle e Lift the roll before moving e Ensure sufficient ground clearance before rotating roll e Stop before releasing the roll e Handle only the number of rolls for which the lift truck is intended Use split arms when handling more than one roll at a time including multi packs Clamp blades e Keep the surface clean e Inspect clamp blades daily e Corners and edges should be well rounded Grind smooth any damaged edges e Some printers attach high density foam pads to the metal clamps to act as a cushion Clamp pressure Lifting capacity depends on friction between clamp wrapper roll e Always adjust clamp pressure to roll weight and paper quality e Check clamp pressure regularly keep a record Too low a pressure may result in dropped rolls Too high a pressure may result in deforming rolls out of round Depending upon its grade a paper roll is worth about the same as a large screen HD TV it is also just as fragile Source WOCG icmPrint Check clamp pressure regularly Source WOCG icmPrint OPTIMISED PAPER HANDLING amp LOGISTICS 1 Lift the roll before moving 2 Stop before releasing the roll 3 Adjust clamp pressure to roll weight and paper quality 4 Use split arms when handling more than one roll at a time Source WOCG icmPrint 6 7 At the Printer Paper onto Press Roll processing efficiency Often roll preparation produces such a surprisingly high and
21. tightly NS SS NS Open tape in acceleration belt path Too fast acceleration tears paper v e S e Splice shields not fully closed or no vacuum 7 Failed splice Inadequate splice tape pressure see also 21 Uneven tape profile from overlaps Tape protective strip not removed No tape applied Dust moisture solvent on open splice tape Glue unsuitable tack temperature humidity Cold roll temperature near core below 10 C Rupture tabs incorrect or turned over covering detection tab SPSPSPSPSBS DSS No splice detection tab sensor dirty 8 Tape or glue overlaps edge of roll 9 Tabs come loose amp stick to expiring web or blanket S 10 Splice detection tab in wrong position 11 Tab in path of folder slitter 12 Too long paster tail causes folder jam see also 10 22 23 13 New roll not aligned to expiring roll or variable roll widths 14 Cocking roller setting incorrect RSS ESSE ESSE ESSE SS ESI USE ESSO ESI SS s 15 Zero speed splicer incorrect alignment to nipping roller Setting and maintenance 16 Debris build up on roller edges v 17 Sensor defective or dirty STS 18 Roll not up to speed 19 Roll will not go to splice position paster status problem 20 Tension drive belts Incorrect tension burred worn v 21 Pasting brush roller dirty worn incorrect pressure see also 7 22 Knife cut too early see also 10 23 Knife cut too late see also 10 24 Knife failed see also 10 17 25 Impro
22. to start of splice cycle A If manual expansion tools are used T wrench air guns ensure they are removed and replaced in their storage rack immediately after they have been used High risk of injury Make sure that the roll unwind direction marked on roll end is correct before loading Losttime to unload roll rotate and reload it creates risk that roll is available too late for splice Expanding Shafts A Expand the shaft before the roll is loaded onto the splicer arms hoist otherwise the roll will be off centre Off centre rolls generate vibrations and tension variations during unwinding causing increased risk of web break creasing and mis register For splicers with roll over roll make splice preparation on the shaft when loaded on to hoist A Follow supplier s procedures to avoid safety and roll damage risks Ensure shaft is locked into position in splicer 4 Remove Wrapper When unwrapped roll acts like a released spring and will tend to loosen This puts additional tension onto splices prepared in advance Cold rolls tend to expand more when warming up Use plastic wooden roll stripper when removing the belly wrapper do NOT use a knife Dispose of wrapper with brown waste Removing the belly wrapper with a knife is less controllable and can result in excess stripping OPTIMISED PAPER HANDLING amp LOGISTICS 7 At the Printer Paper onto Press 5 Slab off White Waste Record amp Dispose
23. unnecessary amount of waste that the productivity of the entire press can be affected Any mis splice following careless preparation or any web break due to an inaccurate check of the roll will cause a lengthy production interruption with the corresponding consequences The successful preparation of the splice greatly depends on the skill and experience of the staff WAN IFRA To achieve a consistent splice efficiency of over 9996 requires a correct roll handling and storage b optimum combination of tape and tab qualities c correct splice preparation and d an efficiently maintained and operated splicer Many press and postpress runability problems are also directly related to poor roll storage and handling and or temperature and humidity variations Weh Break Reporting To speed up help from paper supplier provide them with following information e Order number e Roll number e Paper grade e Roll width e Fault description in case of breaks e Evidence available Electronic Paper printed unprinted e Contact at print plant The roll core and the splice pattern on the paper s outer surface are the two key interface points between the paper roll and the press splicer Both need to provide high functional performance Web Breaks Usually occur when press tension variations become excessive and or coincide with local area weaknesses in the web Paper damaged from poor handling can be a significant caus
24. 5 RH and protected Source ERA from sunlight and dust OPTIMISED PAPER HANDLING amp LOGISTICS 7 At the Printer Paper onto Press Inspect Rolls Before Preparation e Check wrapped ends for cuts glue dirt dust dents water damage e Check roundness e Note any damage with information about size and depth on delivery list with roll number e Take photos of damaged roll parts e Check grade grammage reel width core size For more information on inspection and reporting see Module 2 y 7 Remove end covers with a broad bladed knife 1 Remove End Covers Shields Source WOCG icmPrint If a knife is used care should be taken not to penetrate the roll end A broad bladed knife helps reduce risk A The cutting action with the knife should always be away from the person using it to minimise the risk of injury if the knife slips Always return the knife to a scabbard when not in use Inspect white roll ends for damage cuts glue dents water damage Check roll and core for roundness e Remove core plugs if fitted and inspect core for damage sweep away any dust photo ERA 24 For splicers with chucks the outer 10 15 cm 4 6 must be in good condition For splicers with shafts the core must not be crushed or blocked A Schmidt hammer can be used to test rolls for soft spots Avoid knife damage to roll Source ERA 2 Record Information Read Bar Code and Weigh Record the roll number and other info
25. LEAN amp GREEN BEST PRA Panar CONTENTS 2 FUND Optimise Temperature amp Humidity Paper Rolls Sheetfed Paper Issues Static charge Paper Delivery Inspection Storage Paper Handling ROLL PROCESSING EFFICIEN Web Breaks Splice Faults and Web Breaks Roll Changing amp Splicing Devices Roll Cores Splicing Tapes and Tabs Web Tension a Key to Efficiency Preparing the Roll for Splicing Roll to Web Processing Steps Flying Splicer Straight Patterns Splice Tails Zero Speed Splicing Core Troubleshooting IMPORTANT SAFETY NOTICE A general guide cannot take into account the specificity of all products procedures laws and regulations We therefore recommend that this guide be used only as a complement to Paper Roll Repairs information from suppliers whose safety operating and maintenance procedures along with ae E T applicable local legal regulations always take precedence over this guide Always check DUET OCT EMO oes machine is in its specified safe position before working on any component e g with compressed Paper Handling for Sheetfed Presses air electrical power and gas disconnected Only trained maintenance personnel adhering to Sheetfed Press Feeder safety regulations should perform maintenance work Troubleshooting amp Maintenance Roll to Sheet Feeder Sheet Paper Problems Best Practice Safety C
26. Palletized Paper amp Wrapping Rolls on Pallets TYPE OF PALLET DAMAGE Pallets Rejection Reconditioning Common Pallet Handling Errors IMPORTANT SAFETY NOTICE A general guide cannot take into account the specificity of all products procedures laws and regulations We therefore recommend that this guide be used only as a complement to information from suppliers whose safety operating and maintenance procedures along with applicable local legal regulations always take precedence over this guide Always check machine is in its specified safe position before working on any component e g with compressed air electrical power and gas disconnected Only trained maintenance personnel adhering to safety regulations should perform maintenance work 2 Environmental amp Economic Impact OPTIMISED PAPER HANDLING amp LOGISTICS 5 Roll amp Pallet Handling Techniques Ej Rot amp Pallet Handling Techniques CONTENTS SAFETY FIRST Working Safety Lift Truck Stability Overloading BEFORE STARTING YOUR SHIFT Pre lift Checks Select the Correct Clamping Force Measuring amp Control the Clamping Forte BEST PRACTICE OPERATION Loading Horizontal roll lift ig Stacking Vertical roll lift TROUBLESHOOTING Paper in sheets Energy amp Environmental Issues A IMPORTANT SAFETY NOTICE A general guide cannot take into account the specificity of all products procedures laws
27. Roll damage 1000 mm 40 1250 mm 50 1500 mm 60 100 mm 3 94 36 4 29 6 25 0 90mm 3 54 33 1 26 9 22 7 a 80mm 3 15 29 7 24 1 20 3 P 70mm 2 76 26 3 21 3 17 9 LLL_ 60mm 236 22 8 18 4 15 4 SLL EE 50mm 1 97 19 2 15 5 13 0 A 45mm 177 17 4 14 0 11 7 LILIK 40mm 1 57 15 5 12 5 10 4 LKK 35mm 1 38 13 7 11 0 9 2 UOK 30mm 1 18 11 8 9 4 7 9 UT 25mm 0 98 9 9 7 9 6 6 UN 20mm 0 79 7 9 6 3 5 3 HID 15mm 0 59 6 0 4 8 4 0 UI 10mm 0 39 4 0 3 2 2 7 i 5mm 0 20 2 0 1 6 1 3 J Separated waste Environmental best practice and higher value payment for recycling comes from separating waste 1 Brown waste end covers wrapper Fibre core strip off white waste 2 3 White waste from slab off core 4 Printed waste OPTIMISED PAPER HANDLING amp LOGISTICS 7 At the Printer Paper onto Press 6 1 Splice Preparation Single Multi Function Tape Apply the brake to stop the roll rotating during preparation 1 4 x x Peel off and fold back the first paper layer spire of the new paper roll figure 1 Do not touch the exposed adhesive area on the reverse of the tape as grease decreases its adhesion Apply the tape from left to right with the narrow part of the liner on top Leave a space of about 10 mm 1 2 on each side to prevent exposed adhesive outside of the splice figure 2 Exceptional cases may require preparation to be turned upside down depen
28. allow the roll to be positioned anywhere along the shaft which is generally limited to 1450 mm web width or less Roll shaft systems are simpler than chucks on arms but are more difficult to automate although can be used with a hoist Chucks penetrate only the ends of cores which therefore must be of adequate quality and condition to withstand braking torque Chuck systems are easier to automate and have no width restrictions Both splicer designs use these technologies Core or Belt Acceleration Core braking and acceleration is now common Some flying splicers use belt acceleration and or braking on the outside of the roll to provide good torque control this is no longer common in web offset but is still used in rotogravure 2 f pa i E Flying splicer pastes at full production speed Source Goss OPTIMISED PAPER HANDLING amp LOGISTICS Zero speed splicer with vertical festoon Source Ecograf Roll Handling on Pallets Many printers and converters moving into digital printing do not have roll handling clamp trucks and require their rolls to be supplied on pallets that can be handled manually and with conventional forklift equipment The preparation and handling of rolls and pallets is often a manual process and leads to limitations inlogistics amounts of pallets on trailers and in containers Standing rolls need to be handled with care because of the risk of being deformed on the bottom that can
29. and Environment Hygroscopic in nature paper Is constantly changing to reach equi ibrium with limension and stabilized to a properly controlled and climatized prese Ideal climate control is 45 596 relative humidity a 72 5 F fot press After packaging is opened the paper mill cannot be held responsible d n n ile due to moisture imbalance or other environmental conditions a versely affecting the paper in the printer s facility isti Paper Characteristics of Sheetfed f i rease in rel e Wavy edges usually result when paper is exposed to i enu i idii rb moisture and expan ative humidity The edges absol i di i ition can also res i ly unchanged This condi j i of the sheet remains relativel y when cold paper is unwrapped in a warm pressroom The edidit ill qui densation takes place the unprote tet will quickly cool and as cont 1 npe Min on moisture Cold paper also has less resistance to picking delamination e Tight edges where the edges lose moisture and contract are jum hi al the relative humidity Rh of the pressroom is significantly lower than iv of the paper This condition may also res nen warm paper is unwrapp gai quic isture an ative humidity causing the unprotected paper edges to lose pn tighten while the center of the sheet remains relatively unchanged sappi Paper Conditioning amp Characteristics Sappi Technical Ti
30. ation 3 Splicing tape Dimensions a 20 mm b 100 mm c 50 mm d 3 maximum angle Source KBA The standard pattern is now a straight splice that can be at 90 or at a 1 10 angle to reduce the impact of the splice thickness as it passes through the press The pattern depends on the roll drive external belt or core drive and the selection of either a multi functional or b mono functional tab and tape systems V and W patterns which are occasionally used in some gravure plants for certain conditions gloss paper in winter and for some specific paster types Recommendations for these patterns are not included in this manual but are available from WOCG Guide 1 on www imcPrint org Ensure belt bridge covers tape width x 1 Overlapped paper edge sticks to ink build up on blanket edge tearing the web x 2 Exposed adhesive will stick on to rollers or blanket causing a break Source WOCG icmPrint Apply belt bridge tab in path of acceleration belt tab must be 5 mm wider than belt Holes in belt bridge tab allow correct positioning onto exposed PSA tape the width of which must be fully covered A small nose on the leading edge of this bridge tab helps position it correctly Source tessa Technique to use with discretion Applying grease to the edges of the web alongside the splice zone should be done with care The purpose is to avoid roll edges sticking to blanket at splice point Consequences ar
31. ation This provides uninterrupted printing and higher process speeds particularly of lightweight papers down to 35 gsm and processing of materials that are available only on rolls like plastic film for labels No pile changing is required The roll holds up to five times the number of sheets than a comparable pile Roll to sheet feeding is particularly appropriate for any press using relatively large quantities of a restricted range of paper weights and grades This makes them suitable for most perfecting publication printing particularly on double decker perfecting presses because the second gripper edge is not required reducing paper use by 296 Other paper savings are derived from substrate rolls being generally 5 2596 cheaper than sheets only using the exact cut off length needed and using very light papers efficiently Roll to sheet feeding reduces the effects of electrostatic charges The system runs plastics efficiently and an optional Corona treatment ensures ink receptivity on plastics Use best practice techniques for roll handling described earlier in this Module and also in Modules 4 and 5 Roll on pallets see page M7 OPTIMISED PAPER HANDLING amp LOGISTICS Source KBA Two KBA sheetfed presses equipped with roll to sheet feeders The MABEG device is retrofitable to all brands of presses and available for sheet sizes widths up to 1420 mm Source MABEG P d wa 7 7 At the Printer Paper onto Press
32. bs positioned over the top of the exposed splicing tape in the path of the acceleration belt s to prevent premature opening from air pockets forming during acceleration Bridge tabs are available in different versions PELA depending on the application and paper grade For papers with lower coating anchorage more elt bridge ta NE 3 Splice detection tabs exposed adhesive in the belt path is recommended 4 Splice rupture tabs X Do not use tape liner as a bridge tab as it will separate during acceleration and may cause 5 Folder exit detection tabs li Source WOCG icmPrint a MIS Splice Splice detection tabs Different types a printed solid black for photocell recognition correct density and consistency of printing are essential for reliable detection b reflective for light sensor detectors and c inductive Splice rupture tabs Hold down the outer spire during rotation to prevent air pockets being formed that can burstthe splice during acceleration The die cut perforated tabs break instantly after the splice has been made to release the new roll for unwinding Number and type of tabs are determined by splice speed and paper grade Folder exit detection tabs Aluminium tab used for sorting out splice waste during postpress processes In Europe they are not normally separated from pressroom waste because they are easily removed by filtration during repulping OPTIMISED PAPER HANDLING amp LOGISTICS 7 At the Printer
33. ce overlap thickness and tail running through the press that could damage an inkjet head Manual unwinders take about five minutes to change rolls and prepare a butt splice this significantly reduces the output of high performance digital presses Some manufactures offer hybrid unwinder rewinder systems that by using some automation can reduce roll changeover time by about 50 Manual Butt Splicing Automated Butt Splicing 1 Expiring web wl m Manual splicing When the press is stopped the outgoing web s edges are lightly taped to the 4 Ai eae catenins ie eae cutting table The web is then cut the expired roll removed and a new roll loaded The new web 5 Splicing tape lead is drawn onto the cutting table and lightly fixed by tape on its edges before being cut The Source Hunkeler parallel edges of the two webs are then joined together with a single sided adhesive tape The tapes holding down the web edges are then carefully removed and the new roll is ready to be printed Semi automatic splicing Automated clamps hold the web while it is severed by the cutting carriage A clamp holds the paper in place while the remaining web is rewound on the expired roll A new roll is loaded and moved into position Its web lead is drawn under the clamps where itis tensioned and aligned to the outgoing web and held down while the cutting carriage slices the new paper web The edges of the expired and new webs are joined with a single sided
34. ced creasing particularly on heavier papers The roll position is contained in the roll number Many mills print this position on the label when requested It is best to use position numbers within an order and not mix orders as the positions do not always match exactly between orders Web Tension Variations from Press Line Press line tension settings are specified by the press manufacturer and vary from press to press Generally they are about five times lower than the breaking tension of the paper These tensions need to be optimised over time for variables of different papers blankets ink and dampening Web tension control should be smooth and slow Equipment influences on tension include type of splicer and infeed variation at printing units cylinder pressure setting blanket type packing automatic blanket washers dryer chill rolls and folder During the splice cycle there will be a change in tension profile If there are any weak spots in the web or splice they will be subjected to extra stress and a web break or splice failure can occur Poor Working Practices Lack of ongoing training and motivation often results in incorrect setting operation and maintenance of equipment Poor roll handling can damage and deform rolls Start up Running Splice Running E stop OPTIMISED PAPER HANDLING amp LOGISTICS 7 At the Printer Paper onto Press Preparing the Roll for Splicing PASTER OPERATION SAFETY Different splicer m
35. cessive sheet This system provides good control of sheet position to prevent mis register and paper jams A double sheet detector avoids multiple sheets being fed simultaneously To ensure continuous press operation on high speed presses and or those printing on thick substrates a high pile delivery is available with the option of continuous non stop pile feeding and automated pile handling Optimise paper feeding by keeping paper and board in its protective wrapper until it is required to be used Condition paper to pressroom climate conditions if these are significantly different to external environment Pallet handling with integrated workflow Defining an optimum logistics solution requires an analysis of the complete workflow from truck unloading to production storage systems through to shipment of finished products This might include automated pallet handling and interfaces to ERP and MIS control systems Source KBA OPTIMISED PAPER HANDLING amp LOGISTICS 7 At the Printer Paper onto Press Roll To Sheet Feeder This system allows paper rolls to be run on sheetfed presses with improved process performance because there is no sheet separation step This reduces the number of stops and sheets transported at an angle it also prevents double sheet feeding as each is cut in line transported individually and delivered directly to the feed roller of the press the suction head is not used during roll fed oper
36. cks instead of core shafts integrated infeed web guide and automated webbing up Splice heads using rubber coated rolling nip splice bars are common Higher performance models have a one step operation The Splice Cycle All zero speed designs have a similar splice cycle A The new roll is loaded and its web is led to the splice head and the splice prepared An automatic cycle starts about two minutes before the splice when a klaxon flashing light informs the press crew the splice cycle can also be manually started by the operator B Just prior to the splice cycle the festoon rises to its highest position to store the maximum length of paper to allow a continuous paper supply to the press during the splice cycle during normal running the festoon is maintained by a web brake at a low level to minimise web wander C The splice cycle starts by braking the running roll to a stop which then activates e the nip to bring the running web into contact with the adhesive tape on the new roll lead e the knife cuts the web of the expiring roll D Thesplicer head retracts and the roll is accelerated to the press running speed The expired roll is removed Fig A Unwinding Fig B Festoon fills Fig C Stationery splice Fig D New roll acceleration OPTIMISED PAPER HANDLING amp LOGISTICS 7 At the Printer Paper onto Press Flying Splicer The incoming roll and expiring roll both run at full press speed when the fly
37. crease roll winding position change diameter Save a remaining core with flagging for paper mill OPTIMISED PAPER HANDLING amp LOGISTICS Stickies Slab down a part of the diameter After second break reject the roll from press and change to a different production batch or winding position Collect an unprinted piece of paper with defect Core faults Remove dust from inside cores before putting roll in press Cut off paper from wall inside core if the chuck does not penetrate Reject roll from press if core is out of round or damaged Don t use damaged cores Slipping core protruded layers Nail the core twice each end see recommendations for burst flagging If roll end gets burned reject it from the press Use a different winding or winder position At the Printer Paper onto Press Ed ein a 5 Edge cuts Use emery paper with a fine grain and sand the visible area smooth Slab down a part of the diameter Side damage If side damage is deep use a milling head if flat use emery paper Slab off if damage is less than 7 cm 3 inside roll diameter if higher change roll If rejected to stock then replace the correct roll end shield Wet roll end If roll end shows layer gaps and feels dry then wet the side slightly with a water sprayer If wet area is maximum 3 cm 1 3 thick cut off the part After a second break reject the roll from press Poor mill splice Use abrasive pap
38. d exit the folder without failure of the join High tack adhesive tape functions equally well for zero speed and flying splicer but a low tack zero speed tape cannot be used for a flying splice because it will lead to a mis splice Multi function splicing tape systems for flying splicers combine several functions tapes rupture and detection tabs into one tape to make splice preparation simpler faster and more reliable with reduced risks of web breaks Mono function splicing tapes and tabs systems are still in declining use in some markets and applications Tapes are available in a range of widths to suit varying splice characteristics for flying splice 25 50 mm 1 2 and 12 25 mm 0 5 1 for zero speed Undersize tapes increase the risk of splice failure and oversize tapes add avoidable cost Liquid glue for splicing is now rarely used due to the difficulties of application and the risk of splice failure It is sometimes used in very cold conditions In a number of countries it is also banned due to employee health risks If liquid glue is used avoid drops on surface and reel ends If solvent thinner is necessary use breathing mask Mono Function Splicing Tapes and Tabs These systems are still in use although they have declined in favour of multi function tape systems Splicing tape Double coated tapes using high tack pressure sensitive adhesive PSA on an acrylic base Belt bridge tab Splicers with belt drive require bridge ta
39. ding on splice direction and splicer Use a squeegee or plastic card to apply high pressure across the total width and length of the tape after positioning to ensure optimum adhesion Remove the narrow part of the liner Pull it upwards at a 90 angle to prevent damage to the splitting strip underneath that could cause premature opening during acceleration figure 3 Pull the top sheet tightly over the exposed adhesive figure 4 Expel air between the outer and inner spires so that they lie smoothly to prevent wrinkles or tension difference at the moment of contact between the new and expiring webs Fold back and tear away the excess material of the top paper layer by hand figure 5 Do not use a knife that can damage the tape or paper Use a squeegee for higher pressure when pressing the top paper layer on to the tape Figure 6 Trim both edges of the prepared splice figure 7 This prevents wrinkles caused by air blowing under the top layer during the acceleration of the new roll Remove the remaining liner Pull 90 downwards The roll is now ready to splice If belt acceleration apply belt bridge tab in path of acceleration belt make sure tape width is fully covered otherwise splice preparation will be torn off by acceleration belt see page 24 If splicingtape does nothave integrated detection apply detection label black or aluminum correctly position for optimum tail length apply an aluminum detection label for postpress
40. ds evenly in straight lines with same unwind direction e Not overlap e Have outer rolls protected with roll guards Be used on a first in first out FIFO principle e Show a clean readable label roll number Damaged rolls that may require excessive stripping and paper waste before running Rolls which cannot be run at all Deformed rolls which could reduce press running speed and splicing efficiency Partly used rolls that are returned to storage should be protected from damage and atmospheric changes with a wrapping capable of withstanding minor bumps and acting as a moisture barrier The ends should be protected by reuseable end caps They should have the original roll label reattached or the roll number written on with gsm grade brand Part rolls should be used at the earliest opportunity to maximise warehouse space and avoid deterioration OPTIMISED PAPER HANDLING amp LOGISTICS 7 At the Printer Paper onto Press 5 Pa Der Handling For full information see Modules 4 amp 5 e Use correct equipment and handling procedures to maintain rolls in the best possible condition e Lift truck capacity must be suitable for the rolls being handled Using the wrong equipment can be a danger to personnel Poor handling and storage will result in more damage to rolls higher waste levels and increased risk of web breaks during production Correct use of lift trucks e Ensure the mast is vertical e Clamp
41. e accumulation of grease and paper dust on splice arm and splice roller that may reduce its surface life Apply belt bridge tab in path of acceleration belt tab must be 5 mm wider than belt Holes in belt bridge tab allow correct positioning onto exposed PSA tape the width of which must be fully covered Source tessa OPTIMISED PAPER HANDLING amp LOGISTICS 7 At the Printer Paper onto Press Splice Tails All zero and flying splicers normally have tails For zero speed the position changes with every roll The flying splicer tail is in a constant position that needs to be setto the splice pattern used Tail length should be short to minimise the risk of the tail being cut loose by the folder cutting cylinder which can trigger a jam detector or cause a folder jam Flying splicer tail length can be as short as 100 mm 4 It is influenced by the splice pattern position of splice detection tab and the accuracy of speed synchronisation between the new and running rolls Some zero speed splicers can reduce the tail length to the width of the tape this technique increases preparation time by up to one minute or make an end to end butt splice but this has more complex preparation Normal overlap splice with tail WOCG icmPrint Secure the Tail Splice tail secured with a narrow strip of PSA tape Flying splicers can angle the splice across the web to reduce the impact of the splice running 2 amp 6 emPrint through the pr
42. e RH will decrease as the temperature rises e Avoid storing paper in areas that are subject to extreme temperature changes such as heated objects vents or cold walls Paper should never be stored in direct contact with concrete where it may be exposed to moisture or dampness e Avoid cutting paper sooner than necessary before printing and protect paper with moisture proof wrapping immediately after cutting e Paper is not an efficient heat conductor Therefore allow sufficient time to let the paper adapt Itself to the temperature in the workshop Properly conditioned paper runs with a broader operating window on press See paper condition times Module 3 Do not open the paper wrapping until printing is about to begin The wrapping protects the paper from fluctuations in temperature and humidity Avoid damaging the paper wrapping and carefully re wrap remaining pallets e IR and UV Mercury dryers can drastically reduce paper RH and should be used cautiously e During drying the paper should not be exposed to extremely low temperatures as this would significantly extend drying times e For wavy edged sheets try conditioning the paper through the press on impression without moisture and pre warm with the IR dryer or strip heaters above the feedboard Static Electricity in Paper Static charges commonly occur when very dry paper is processed in low air humidity conditions The critical lower limit is 30 4096 RH for both the paper
43. e centre of the sheet remains relatively unchanged Causes include excessively dry paper extremely high air humidity in the pressroom damp proof wrapping not used during transport or storage in humid conditions cold paper unwrapped in a warm pressroom cold paper also has less resistance to picking and delamination Tight edges Occurs when sheets of normally humid paper are subjected to exceedingly dry air humidity In this case moisture is absorbed from the edges of the sheets which as a result shrink in relation to the centre This mainly occurs during winter if the RH of air in heated non conditioned or non humidified working spaces drops significantly When warm paper is unwrapped in a cold pressroom the immediate surrounding air warms quickly and lowers its RH causing the unprotected paper edges to lose moisture and tighten while the centre of the sheet remains relatively unchanged For either problem it can be helpful to cut out the blanket packing on the outer non image edges to allow the sheet some relief during impression squeeze OPTIMISED PAPER HANDLING amp LOGISTICS 7 At the Printer Paper onto Press Minimise Climate and Paper Problems Air moisturising systems are commonly used in paper processing environments and are particularly helpful when air humidity is very low during winter To avoid wavy edged paper when pressroom relative humidity is too high turn pressroom heat up to a maximum of 29 C 85 F Th
44. e of web breaks Causes are typically attributed to source Goss 30 Paper 20 Poor operating procedures amp equipment faults 5096 Unknown reasons includes poor handling amp Storage Paper quality is generally consistent and excessive web breaks due to paper faults are rare automated roll handling considerably reduces risk We recommend web break causes should Recommendations ERA Paper First Aid ie be treated under two classifications e Paper defect manufacturer s responsibility e Roll handling and storage damage transport and or printer s responsibility Web break frequency varies between printing method print job run length type of printing DN finishing consumables experience of operators maintenance housekeeping environmental 2 BEST PRACTICE GUIDE FOR WEB OFFSET PRINTERS m iv conditions etc 4 rio A single defect does not necessarily impair runability however the combination of two or more Will affect press performance Many faults are rare and unlikely to be repeated throughout the Web break prevention amp diagnosis roll e g holes or cuts The standard procedure after a web break is to restart with the same roll Normally if there are two web breaks in the same roll then change it for a new one that preferably has a different position in the tambour jumbo roll or a different manufacturing batch Contact your paper supplier to deal with problem What can be done to m
45. eet Incorrect clearance buckle plate to sheet Side guide touches sheet before it stops against front guides Incorrect guide setting Incorrect spring setting of upper to lower guide rollers Too little sheet clearance at front guides Too much gripper bite Front guides do not clear sheet edge Incorrect sheet transfer synchronisation Tension of grippers too weak or uneven Excessively high ink tack Poor release of blanket Grippers not closing simultaneously Out of line front guides Too tight wheel tension on register table Paper slips out of some not all grippers Wavy edge paper from unwrapping cold paper or if press room RH too high Tight edged paper Side edges of sheets pick up moisture between printings amp become longer Wavy or tight edged paper OPTIMISED PAPER HANDLING amp LOGISTICS SHEET PAPER PROBLEMS ON PRESS RELATED TO STORAGE AND HANDLING Solutions Lower feeder pile Raise feeder pile Adjust air blast nozzle to correct height and reduce air pressure Clean if dirty Replace if worn Check and adjust suckers if needed Check vacuum timing Air the paper flip through to unstick Poor guillotine blade Paper curl wavy edges out of square Insert ionizing air cartridges in air blast lines Maintain RH above 35 ideally 50 5 Use just enough air to float top few sheets Or repile and roll the lifts to free sheets Clean any clogged powder oil and debris Align nozzles correctly Needs preventive mainte
46. er running roll diameter Change core diameter from 76mm to 150mm mom ow Contact core supplier to identify right core type and asses paper roll residual runability characteristics Paper web flutters at the edges near the splicing diameter Core has probably deformed due to radial pressure 1 Use stronger core grade 2 Usehigher wall thickness 3 Contact core supplier for other options and solutions Loose cores The whole core slides out from the roll at the printing press and it seems there is no paper pressure left between the core and paper Check the length of core and compare to roll width has it shrunk Check the delivered paper moisture Check the delivered core moisture Check the core package wrapped or not Check the humidity at core warehouse and the way from warehouse to winder ee o mw If necessary change the core moisture specification core packaging and handling during operation OPTIMISED PAPER HANDLING amp LOGISTICS 7 At the Printer Paper onto Press Paster Splicer Diagnostics Splice preparation Burst Fail Mis Break Flying Zero v e e o e Failed roll fault inspection prior to loading Rolls unwrapped too early v SPS DS Excessive vibrations v Wrong roll unwind direction flying paster SS SS SS ENS Incorrect splice pattern type e ee era cel ce ae Splice pattern bursts open before splice Air pockets Dynamic roll expansion see also 2 Rupture tabs applied too
47. er to remove overlapping If layer is too thick slab down the layers to position of mill splice maximum 3 cm 1 3 of diameter reject roll if protruding layers are deeper Belly damage Slab down affected layers Before use check core roundness and inner core wall due to broken areas Check shape if out of round or core is damaged reject the roll OPTIMISED PAPER HANDLING amp LOGISTICS 7 At the Printer Paper onto Press Sheets amp palletised paper Sheetfed Press Feeder The feeder and lay system takes sheets of paper or board from a pile to deliver individual sheets in exactly the same position to the press grippers A suction head feeds separated sheets from the top of the pile on to the feedboard A classic feed suction head uses low pressure air generated by a vacuum pump and it is adjustable for speed sheet size and weight Newer suction head nozzle technology generates vacuum and compressed air directly inside the suction head during each process step for smoother sheet control at all speeds this system eliminates rotary air valve hoses and air control is 5096 more energy efficient and has less wear The sheets are then moved down the feedboard by suction belts into the front and side lays to position the sheet accurately before it is taken into the press by the gripper system Stream feeders work at a speed slower than that of the press and the edge of a sheet of paper overlaps the front edge of the suc
48. eshooting amp Maintenance OPTIMISED PAPER HANDLING amp LOGISTICS 2 7 At the Printer Paper onto Press Poor sheet feeding amp jams Static electricity Brittleness Piping paper rolls Shrinkage on open rolls Burst splice Splice failure General web break risk Climate and Paper The interaction between climate and the processing of coated papers in printing and finishing Climate and Paper in the Press Room Sappi technical brochure Source www ideaexchange sappi com Fundamental paper conditions for printers For a printer substrates are the single largest expense 50 70 of total costs making it essential to minimise waste from all causes Paper and associated waste comes from several areas transport handling storage and preparation for use Two keys for management of productivity are measurement and people Measure the right things and communicate the measurements to people in a manner that encourages corrective response War on Waste II Roger V Dickeson GCA Optimise Temperature amp Humidity Temperature Humidity Lower 20 25 C 68 74 F Higher Lower 50 5596 RH Higher e e e e e oO e o o o e o e e e Piping occurs in lt 10 outer layers and increases risk of creasing Paper that is not in balance with its storage and operating environment can lead to serious printing problems such as static charge and dimension variations along with set off tensile wea
49. ess but this leaves part of the tail longer than the minimum cut length Many printers reduce this risk by securing the loose tail by Applying a second narrow strip of PSA or glue to hold down the tail or use an aerosol glue type 3M Post i to secure the loose area Splice Detection Tab Position Cutting Point When preparing rolls there are two simple things to remember for tails The relative length of the tail distance between tab and cut is determined by the position of the splice detection tab The same relative tail length is possible for all splice patterns The effective tail length distance between cut and end of splice pattern is determined by the type of splice pattern used Splice tab position Irrespective of what splice pattern is used the distance between the end of the splice pattern and the cut web is always the same providing the splice detection tab is correctly positioned The tab is always in the same relative position for all splice patterns The effective tail length is determined by the type of splice pattern Detector position A constant tail length error can be caused by a change in the relative position and or angle of the splice tab detector Every Tail Tells a Story The causes of many splicing problems can be rapidly diagnosed by examining the splice tail Many are simple and easy to fix by the splicer operator or in plant technician with the aid of the user manual TAMIR
50. exit if required Release splicer brake Rotate roll to avoid dust and moisture condensation falling onto tape Dust and condensation on the tape surface reduces its adhesive qualities If possible only remove the protection strip liner from the adhesive just prior to the splice cycle Release splicer brake Rotate roll to avoid dust and moisture condensation falling onto tape Set lateral position of new roll to align it with running roll to avoid the high risk of splice failure or web break OPTIMISED PAPER HANDLING amp LOGISTICS 7 At the Printer Paper onto Press 6 2 Splice Preparation Mono function Tape and Tabs Apply the brake to stop the roll rotating during preparation 1 Fold back the first paper layer spire and slit along the folded edge Expel air between the outer and inner spires so that they lie smoothly X Wrinkles cause tearing and separation of the top layer from the surface during acceleration 2 Use rupture tabs to close the roll system The distance between tabs 100 150 mm 4 6 is related to paper weight and press speed Outer tabs should be 25 mm 1 from the edges Use line printed on the tab to position adhesive free zone under the line pointing to the inner spire of the roll for easy opening at pasting X Do not apply tabs too tightly or they may break in advance of splice x Always close the top of the splice pattern to prevent creating air pockets that can cause splice failure X Inc
51. for recycling is not suitable for deinking it is usable in other paper recycling Waste Storage amp Shipping The shipping area is often the best place to position waste Paper waste can be collected automatically by suction or conveyors or manually Conveyors require sufficiently heavy waste to function correctly They are energy efficient because they do not aspire air from the factory conserve the internal temperature and are quieter than other systems Compaction is the most efficient system to reduce paper volume but needs careful evaluation of space required noise impact and cost Horizontal compaction balers can be fed manually or combined with automated trim extraction systems These systems generate dust and should be located away from manufacturing In certain special cases security printing waste signatures and makeready sheets may need to be shredded Ask your waste collector to evaluate your operation including the level of sorting white paper printed laminated to develop an adapted waste management concept for the printing company et b European List of Standard Grades of Paper and Board for Recycling Guidance on the revised EN 643 2013 revision European List of Standard Grades of Paper and Board for Recycling Guidance on EN 643 revised 2013 Source CEPI processes For more information see Guidance on the revised EN 643 from CEPI OPTIMISED PAPER HANDLING amp LOGISTICS
52. g to safety regulations should perform maintenance work Best Practice A Safety 2 x Poor Practice Environmental amp Economic Impact OPTIMISED PAPER HANDLING amp LOGISTICS 4 Paper Handling Equipment CONTENTS PAPER amp BOARD Climate amp Fibre based Products Types of Paper amp Board PAPER ROLL Roll Cores as Process Components Roll Wrapping Labels amp Bar Codes SHEET PAPER Palletized Paper amp Wrapping Rolls on Pallets E iPaper Handling Equipment A IMPORTANT SAFETY NOTICE A general guide cannot take into account the specificity of all products procedures laws and regulations We therefore recommend that this guide be used only as a complement to information from suppliers whose safety operating and maintenance procedures along with applicable local legal regulations always take precedence over this guide Always check machine is in its specified safe position before working on any component e g with compressed air electrical power and gas disconnected Only trained maintenance personnel adhering to safety regulations should perform maintenance work Best Practice A Safety 3 2 A Xx Poor Practice Environmental amp Economic Impact OPTIMISED PAPER HANDLING amp LOGISTICS 7 At the Printer Paper onto Press CONTENTS PAPER HANDLING TOOLS Paper Rolls Have Different Wrappings Choosing Truck and Clamps Tasks amp Clamp Tr
53. g unloading and do not allow rolls and pallets to remain in the rain sleet or snow Clarify in advance under which weather conditions loading operations must be stopped if handling damage occurs then follow the set procedures Stevedores should follow the loading plan under the supervision of the vessel s offic personnel The maximum load capacity of the cargo decks should not be exceeded Therefore it is important to stow the rolls according to the stowage plan and designed weights Stow one order at a time according to the diameters Rolls must be stowed tightly nested together jfthere are rolls with different diameters in the same pile tower the larger diameter rolls must be on the top to prevent smaller diameter rolls moving Module 6 Transport Alpha version 1 21 09 15 1 New text in blue type Delete text IMPORTANT MS Word corrections are preferred to PDF because they ar much easier to manage when there are multiple reviewers Please use the very simple correction indications below OPTIMISED PAPER HANDLING amp LOGISTICS 7 At the Printer Paper onto Press W At the Printer Paper onto Press CONTENTS 2 FUNDAMENTAL PAPER CONDITIONS FOR PRINTERS 2 Optimise Temperature amp Humidity 3 Paper Rolls 3 Sheetfed Paper Issues 3 Static charge 4 INTERNAL LOGISTICS FOR PRINTERS 4 Paper Delivery Inspection 4 Storage 5 Paper Handling 6 ROLL PROCESSING
54. icer Straight Patterns Splice Tails Zero Speed Splicing Core Troubleshooting Troubleshooting amp Maintenance Paper Roll Repairs SHEETS amp PALLETISED PAPER Paper Handling for Sheetfed Presses Sheetfed Press Feeder Roll to Sheet Feeder Best Practice A Safety E LM A x Poor Practice Environmental amp Economic Impact Sheet Paper Problems Climate and Edge Problems Minimise Climate and Paper Problems Static Electricity in Paper SEPARATE AND RECYCLE WASTE OPTIMISED PAPER HANDLING amp LOGISTICS How to make corrections To become a reviewer simply go to the World Printers Online Forum https shar es 1TvMACo and then to Best Practice Guide under Printing Paper to download modules as PDFs and Word documents Two methods of correction are possible 1 Post short comments on to the Forum or 2 Make larger changes on the accompanying manuscript document and send directly to the editor Nigel Wells vimwQwanadoo fr f you would like to suggest additional material please send as Graphs Charts Excel drawings eps vector format Illustrator photos JPEG format 300 dpi with minimum compression e Any material submitted includes copyright authorisation to be used in the guide unless otherwise indicated e We will acknowledge the names and companies of participating reviewers unless otherwise indicated Loading
55. ing roll change is made Splice preparation requires precision correct tapes and tabs The Splice Cycle A The new roll is loaded and splice pattern prepared while the running roll is being unwound An automatic cycle starts about two minutes before the splice when a klaxon flashing light informs the press crew the cycle can also be manually started by the operator The arms turret are rotated into the splice position the splice arm carriage pushes the running web to about 10 mm 0 4 from the new roll surface The new roll is accelerated by either a belt on the roll circumference or by a core drive to match the speed of the running roll 0 5 1 The new roll is normally automatically aligned to the running web 1 mm 0 04 The PLC synchronises all splice parameters running web speed minimum roll at splice new roll circumference speed position of detection tab and automatically triggers the splice The running web is pushed by roller or brush against the surface of the new roll about 1 5 m 60 before the splice pattern the roll is pasted on to the running web and the splice opens to release the new web d The knife cuts the web of the expiring roll just after the end of the splice pattern splice tail Tension control brake is transferred to the new running roll M The expiring roll is braked to a halt and the splicer carriage returns to its home position The arms turret are rotated into the running posit
56. ing and storage defects will result in less physical damage to the paper minimising paper losses and production difficulties arising from deformed rolls and local paper weaknesses on the edges and surface Paper Delivery Unloading Use optimised techniques for unloading the specific delivery vehicle This can be a frequent source of damage See Module 5 Inspection For full information see Module 2 Any visible damage needs to be reported at every transit point Failure to note damage on delivery documents and timely reporting to the supplier can result in a claim for damaged paper being rejected nor does it allow fault analysis to be made to identify and resolve the cause of damage Rolls should be inspected on arrival and any visible defects should be noted on the delivery documents CMR Additionally digital cameras can be used to document damage for timely transmission and send by e mail to those needing this information For insurance purposes any complaint to the supplier must normally be made within 48 hours Failure to note damage on the delivery documents could result in any claim for damaged paper being rejected Storage For full information see Module 3 FA The warehouse should have these attributes e Dry e Clean e Even level floor e Sufficient working space e Good lighting e Roll bay markings on the floor e Storage temperature should be similar to the pressroom Rolls should e Be stacked on their en
57. ing from brake interferes with running roll solenoid If dancer fills out before or after splice Speed signal incorrect Incorrect brake transducer adjustment SOLES ESSE ESSE ES ES ESSE ES ES ESSI ESSE ESSI ES ESI ES ES EST ESI ES ESI ES ES M Incorrect or faulty dancer POT encoder setting OPTIMISED PAPER HANDLING amp LOGISTICS 7 At the Printer Paper onto Press Zero Speed Vacuum Bar Design With Split Splicer Head A Guide the web around the upper guide roller and unwind the paper until it touches the floor Push and hold the Open splice head half button until the splice head half near the roll for which the splice has been prepared is fully open Push the Handbrake button to brake the roll and extend the chucks to clamp the roll B Push the Vacuum button to activate the vacuum pump Pull the web taut without creases Read out the web position from the ruler and compare it to the web position of the running roll Correct the lateral position of the running roll Push the web against the vacuum bar The vacuum holds the web in the correct web position C Placethe tip of the knife in the slot over the vacuum strip and cut off the web in a straight line Apply tape to the web along the full web width D Pull the backing film off the tape Push and hold the Close splice head half button until the splice head half has fully closed OPTIMISED PAPER HANDLING amp LOGISTICS 7 At the Printer Paper on
58. inimise web breaks 1 Measure and analyse missed splices and web break causes to identify priority areas for improvement 2 Regularly share with staff data on economic value of paper waste and web breaks 3 Introduce best practice to reduce web break probability from both individual and combined causes 4 Train and motivate staff to apply best practice systematically Web Break Prevention amp Diagnosis provides a systematic best practice approach Source www icmprint com OPTIMISED PAPER HANDLING amp LOGISTICS 7 At the Printer Paper onto Press 7 Mis Splices Any failure of the splice during the cycle from when the splice arms start to move or zero speed festoon begins to fill to the moment the splice leaves the folder without disturbing the web causing a press stop or excessive waste During the splice cycle there will be a change in tension profile and any weak spots in the web or splice will be subjected to extra stress and a web break or splice failure can occur Some causes can be defined as 1 Burst splice When the new roll bursts open prior to splicing 2 Failed splice When the new roll does not paste to the expiring web Some Paper and Splicing Problems at the Printer Splicing failure reason Burst Fail Paper delivery printer inspection failed to identify roll fault e Poor storage at printer Handling damage at printer Rolls unwrapped too early e Excessive roll vibrations Wr
59. ion Fig A Unwinding Fig B Splice cycle Source Goss Contiweb OPTIMISED PAPER HANDLING amp LOGISTICS 1450 1036 There are numerous flying paster designs however they all have a similar splice cycle The main differences are in the way rolls are supported rotated accelerated and braked this is a compact model Source B amp W MEGTEC Flying splicers for heavy and wide rolls are equipped with automatic loading This can include a core container left into which the expired roll can be placed Source KBA Fig C Loading 7 At the Printer Paper onto Press ovn B0 47 Automation Issues EE T Maximum 5 mm off center 0 2 Paper roll 1270 mm 50 Roll buffer system in heatset web offset Source Goss Out of round tolerances for automatic handling Source KBA splicer by forklift AGV stub container at the High Press Speeds and Larger Roll Dimensions Increased offset press speeds up to 20 m s means reduced intervals between roll changing Some presses have increased roll diameter from 1250 mm to 1500 mm 50 to 60 to reduce roll changes by 3196 however this increases roll weight by 4496 Offset web widths have also increased to between 2000 to 2860 mm This means that rolls of up to 7 5 tonnes need to be handled requiring automatic
60. iral bindings etc Recommendations of EN 643 are to use Guidelines for Recovered Paper Quality Control and Responsible Sourcing and the European Recovered Paper Identification System RPID This Is to identify paper for recycling purchased received stored and consumed in paper mills to improve traceability see www recoveredpaper id eu Quality Issues Prohibited materials with zero tolerance these represent a hazard to health safety and environment for example medical waste contaminated products of personal hygiene hazardous waste organic waste including foodstuffs bitumen toxic powders and similar Unwanted material not suitable for the production of paper and board with a tolerance level of 1 3 depending on grade that might include non paper components with tolerance levels of 0 25 396 of paper and board not according to grade definition or detrimental to production or not suitable for deinking when intended for deinking Non paper components include metal plastic glass textiles wood sand building and synthetic materials Moisture content recovered paper and board should have the same moisture as the naturally occurring level If it is over 1096 of air dried weight the excess weight may be claimed back Deinking paper products not suitable for deinking belong to unwanted material This currently refers to most flexographic printing inkjet liquid toners and to some UV cured printing If paper and board
61. kness folding resistance and surface smoothness Paper being a porous material humidity control becomes crucial temperature has a significant influence on relative air humidity Air can contain only a specific amount of moisture vapour at a given temperature the higher the temperature the more moisture air can absorb Relative humidity RH is the proportion of absolute moisture content in relation to the highest possible moisture content at a given temperature RH is often variable during the course of a day and by season Paper will adapt itself to the humidity of the surrounding air by either absorbing or exuding moisture This tends to occur e During summer periods that are hot and humid in non conditioned warehouses and pressrooms e When damp proof wrapping is not used during transport or storage in humid conditions e n winter when cold paper is unpacked in the warm air of a pressroom the surrounding air temperature will drop sharply causing a rapid rise in air humidity The paper edges then absorb moisture making them swell in relation to the centre of the sheets Best practices for optimised paper condition for printing e Paper stability is achieved at 20 C to 25 C 68 77 F and 50 55 RH relative humidity e Paper should remain wrapped in its packaging until any difference in temperature has been balanced out The time needed depends on the temperature difference the size of the stack and the conductivity of the paper
62. lead to unwinding problems at moderate to high speeds ON bt E L Fr Ld E i p dm Be al LT j i i Uf T Standing roll loaded on to a pallet and securely chocked both sides Source UPM 7 At the Printer Paper onto Press Horizontal roll and festoon Source WOCG icmPrint Horizontal zero speed splicer with automated roll loading Source Goss Zero Speed Splicer Splicing occurs when the web is stationery while a festoon of paper provides a temporary stock of paper for the press to run at full speed Splice preparation is relatively simple and the tape requires only a moderate performance Advantages of zero speed designs over flying splicers include their flexibility in unwind direction and choice of the web side to be on top no restriction on the roll splice diameter allowing small rest rolls to be used up and changing the web width is simpler The two principal zero speed configurations are Vertical festoon with roll over roll This provides simple braking acceleration control easy web up with minimum floor space required it uses core shafts and requires a hoist to load upper rolls Central loading twin webs are common Horizontal festoon Same functional advantages as vertical but splicer is lower in height and floor loading does not require a hoist commonly equipped with roll arms and chu
63. limate and Edge Problems Minimise Climate and Paper Problems Poor Practice Environmental amp Economic Impact Static Electricity in Paper OPTIMISED PAPER HANDLING amp LOGISTICS ALPHA VERSION Optimised Paper Handling amp Logistics Participating associations o e 5 2 e Idealliance 4 NODA icmPrint WAN DIFRA Optimised Paper Handling amp Logistics is a unique international cross industry collaborative project across the supply chain to produce a common best practice tool and global reference for suppliers transporters and printers to improve their economic and environmental efficiency The result will be an e book of around 180 pages available at no cost to users Become an Alpha version reviewer This Alpha version is for open industry comment to help ensure that the final publication is as comprehensive and complete as possible To become a reviewer simply go to the World Printers Online Forum https shar es 1vMACo and then to Best Practice Guide under Printing Paper to download the different modules as PDFs and as MS Word documents The Guide consists of seven modules that will be independently available for review 2 Inspection diagnosis reporting amp repair Z Inspection Diagnosis Reporting amp Repair CONTENTS Defining Delivery Responsil O daMOTems Damage Reasons and Coding Inspection Recondition or Rejection TYPE OF ROLL DAMAGE
64. milar manner to paper recycling keep a separate grade e Damaged rolls of paper not returned to the paper mills can be fixed into smaller usable rolls or converted into wrapping paper Paper and board for recycling are classified by EN 643 2013 into 95 grades in five groups ordinary medium high craft and special grades There are specific requirements for deinking grades and the list includes grades in which non deinkable papers count as unwanted material Plastic Waste Availability and conditions for plastic recycling are highly variable and should be assessed locally Separate plastics into different classes for a higher value recycling Wooden Pallets Reuse or return to the supplier wherever possible unless sold for reuse mM l e PETE strapping bale used strapping in the same way as recovered paper or granulate it M a a E R S cut into small pieces for sale to either the manufacturer or a certified recycler pallet recyclers who either repair them uM MEN or use the components to assemble new e ABS and PS plastic spools primarily from postpress stitching operations sort spools by pallets and shred any remaining waste grade and sell them to a scrap plastic recycler for landscape mulch boiler fuel etc e LDPE plastic stretch film stretch film can be collected and baled in house and sent to a Remaining scrap should be disposed of recycler or broker by a wood recycler e Clean plastic containers that are not
65. mperature effects on ink drying A high humidity balance of the paper stack can significantly extend ink drying times The effect is pronounced above 60 RH leading to drying times up to three times longer than normal Extended drying times can also occur when the stack of printed paper is too cold Static Charges Static commonly occurs when very dry paper is processed in low air humidity conditions The critical lower limit is 30 40 RH for both the paper and the pressroom See Module 7 OPTIMISED PAPER HANDLING amp LOGISTICS Dynamic roll expansion after wrapper removal When unwrapped the roll acts like a released spring and will tend to loosen putting additional tension onto splices prepared in advance High humidity in the pressroom exacerbates the problem Cold rolls tend to expand more when warming up Source WOCG icmPrint Paper stretch is caused by imbalance of paper RH to that of pressroom Source icmPrint Relative humidity in a paper pile can be measured with a sword gauge Source Sheets failing to feed properly because of paper curl wavy edges or out of square can be minimised by conditioning paper correctly in pressroom Source icmPrint 4 7 At the Printer Paper onto Press t iu C KO E 4 UL Correctly stacked rolls x Poorly stacked rolls Source WOCG icmPrint Internal logistics for printers Preventing handl
66. nance Adjust wheel timing Put new rubber on wheels and re set Replace tapes Clean Repile rolling sheets downwards to uncurl Install static elimination or RH too low Adjust clearance Adjust to stop sheet bounce buckle Reset Use only steel or soft brush wheels Replace or retrim the paper Clean and re set gripper uniform tension Replace worn gripper pads Check for worn parts Adjust timing or front stops Re trim paper Adjust pusher plate Re set Check and adjust timing of side guide and slow down Re set Adjust setting to the paper being printed Adjust clearance of hold down springs Check sheet timing to front stops Re set front guides to reduce bite Check and adjust front guide timing Clean service and re set gripper systems Check grippers for uniform timing Reduce ink tack Use a quick release blanket See manufacturers service instructions Re align guides Adjust wheel to minimum tension Clean and service gripper pads Do not unwrap until at room remperature Consider dehumidifier or air conditioning Occurs if paper left unwrapped in dry area Humidify press room Place moisture vapour proof cover over pile after first printing Use flat paper to prevent distortion Follow manufacturer s instructions Air humidification systems improve productivity when humidity is too low Source PDI oma sere Paper Conditioning amp m lelp Line T eov Tem Characteristics i Paper
67. nd printing press safely Only the press manufacturer in cooperation with core and paper suppliers can provide information about safe unwinding speed for roll width weight speed combinations and core diameter required 76 or 150 mm 3 or 6 See Module 1 for more information Residual Roll Explosion Risk High speed presses with web widths over 2000 mm require a higher critical speed axial E modulus of core divided by its density If this value is incorrect the residual roll can explode and may cause serious injuries Therefore these offset splicers should be enclosed within safety cages during operation these are already used in publication gravure The planned ISO 12643 standard requires a safety barrier against core fragments when web speed exceeds 15 Web width 1960 2800 mm 77 110 inches m s or webs are wider than 2000 mm 150 mm 6 core 75 mm 3 core Speed 8 18 m s 1575 3600 fpm This chart indicates core diameter requirements in relation to printing speed and web speed with a splice Dynamic strength is measurement to estimate roll weight It does not correlate web vibration eter of 120 mm 4 77 Always check with the press P i M a manufacturer and core supplier particularly when Critical speed is depending on core E modulus divided by its density a high value is required in the transition zone from 75 to 150 mm 3 6 core to avoid residual roll explosion risk at higher web width and pr
68. nd sorting A Rollarms are adjusted to the correct width for the roll being loaded plus supplier s tolerance For splicers without any form of assisted loading it is a good idea to paint reference lines on VEMM i Ink jet printing on roll end shows roll number weight the floor for common web widths to allow better line up of rolls before they are moved into the unwind direction and mill splice position arms Edge damage is common during loading from collisions with splicer arms or chucks and Source WOCG icmPrint causes avoidable paper damage OPTIMISED PAPER HANDLING amp LOGISTICS Ensure chucks are fully retracted and free of debris before loading and roll brake is switched on Source WOCG icmPrint Always expand air shaft before roll is loaded Source WOCG icmPrint Use a roll stripper to remove the belly wrapper Source WOCG icmPrint 7 At the Printer Paper onto Press Chuck pasters Roll Loading Safety Check Make sure chucks are fully retracted and free of debris before loading and roll brake switched on A Verify chucks are fully inserted on both sides Risk is that roll could come free of chucks to create a potentially serious accident damage to roll and splicer A Chuck jaws are fully expanded into core If soft cores are used there is a risk that the chucks will settle into core If chucks do not provide continuous automatic expansion then the chucks should be checked for expansion just prior
69. odels have their own specific operation Therefore this general guide can under no circumstances replace the supplier s instructions Before operating the splicer all staff concerned must know the manufacturer s safety regulations operating instructions and maintenance procedures Paster makeready Set roll width adjust width between splicer arms to roll width clearance specified Core waste This is the preset length of paper to be left on the core at time of splicing It is determined on the basis of minimum length to avoid web running off roll and consequent press stop The last wraps around the core may not be suitable for printing due to wrinkles or embossing Set low start up tension setting to minimise risk of web break at low speed Web up splicer after roll is loaded following the splicer manufacturer s instructions Ensure web guide is centred Ensure web cocking device is in neutral position Some zero speed and flying pasters can cock either the festoon or outlet roller This is used to compensate for deformed rolls It Is essential that this device is in a neutral position when not required as otherwise it will create massive instability in the running web Paster and Infeed Tension Experience identifies these starting points to develop optimum settings on each press in conjunction with those of the manufacturer Values depend on type of paster winding hardness printing cylinder assembly gummi steel or rubber rubber e
70. oduction speeds This may require diameter see Module 1 for more details core roll diameter to be increased from 76 to 150 mm 3 or 6 BONOS OTO A A movable barrier in front of the splicer protects operators in case of a residual roll explosion The door is automatically closed before and after splicing and at a given web speed and roll revolutions Source KBA OPTIMISED PAPER HANDLING amp LOGISTICS 7 At the Printer Paper onto Press ocmeem 7o Splicing Tapes and Tabs _ Adhesives all with high tack Coldset Heatset Pub Gravure AM c Repulpable adhesive e e Repulpable heat resistant adhesive e Climate resistant adhesive e o Tape opening force Low Moderate High A nl Core driven splicer G Different characteristics and dimensions are used Belt driven splicer amp e for different splice conditions Please check with Fragile paper quality e e your supplier to ensure using the correct tape for the conditions in your environment printing substrates and uL Ld Modern splicing tapes allow a straight line splice pattern that has become the market standard for flying splices and has largely replaced complex V and W patterns which are occasionally used in some gravure plants for certain conditions gloss paper in winter and for some specific paster types Pressure sensitive adhesive PSA tapes must paste the new web to the running web with sufficient adhesion to pass through the press dryer an
71. olls can be cocked on some models OPTIMISED PAPER HANDLING amp LOGISTICS Core waste is set either as 1 radial thickness or 2 linear length To minimise either having too little core waste or too much these settings can be changed when the press changes from a very thick to a very thin paper or vice versa Attention the external of cores are variable Source WOCG icmPrint A Parallel festoon rollers B Tapered rollers to self centre the web C Off centre half web requires tapered rollers to be taped Source WOCG icmPrint 7 At the Printer Paper onto Press Roll to Web Processing Steps Preparation with the roll on the splicer is recommended because it is ergonomically efficient and minimises damage and waste An automated central roll preparation station is used at some installations but requires careful transport of rolls to the splicers A few very high volume printers use fully automated systems Roll preparation area needs to be dry even free of hard particles and clean Best practice roll handling avoids damage that frequently leads to excessive paper waste and web breaks Close gates and doors near the splicer to control draughts and dust temperature and RH variations X Premature removal of the wrapping increases the risk of dimensional instability from atmospheric variations and accidental damage to the white paper Manual On Paster Preparation roll placed next to splicer Remove end c
72. ong roll unwind direction flying paster Incorrect splice pattern type co N Cc OF FP C9 N gt Splice pattern bursts open before splice Air pockets Dynamic roll expansion see also 2 Rupture tabs applied too tightly Open tape in acceleration belt path Too fast acceleration tears paper Splice shields not fully closed or no vacuum 9 Failed splice Inadequate splice tape pressure Tape protective strip not removed No tape applied Dust moisture solvent on open splice tape Glue unsuitable tack temperature humidity Cold roll temperature near core below 10 C Rupture tabs incorrect or turned over covering detection tab No splice detection tab sensor dirty 10 Tape or glue overlaps edge of roll 11 Tabs come loose and stick to expiring web or blanket 12 Splice detection tab in wrong position o 13 Tabin path of folder slitter 14 Too long paster tail causes folder jam 15 New roll not aligned to expiring roll or variable roll widths 16 Cocking roller setting incorrect 17 Zero speed splicer incorrect alignment to nipping roller e 18 Incorrect setting and or maintenance issues o e Not applicable to multi function splicing tapes OPTIMISED PAPER HANDLING amp LOGISTICS Mis e Break e Splicer type Flying Zero o o e e e e e o e o e o e o 9 e e o e o e o e o amp o o o e e e e e o o o e o e 7 At the Printer Pa
73. orrect rupture tab position increases breaking strength and may result in a failure to 3 v open bh eS A 3 Applythe tape along the splice profile 2 mm 0 08 from the edges on all three sides Do not 2 remove protective cover of tape X Do not allow tape to overhang the roll edges X Do not stretch the tape and avoid pleats X Do notapply tape tabs in the path of folder slitter wheel path possible web break of a ribbon 4 Usea squeegee or plastic card to apply high pressure across the total width and length of Y the tape after positioning to ensure optimum adhesion i 5 Use scissors to cut off ears of leading edge next to the external tabs to improve edge profile 6 Remove PSA tape protective strip 1 If belt acceleration apply belt bridge tab in path of acceleration belt make sure tape width is fully covered otherwise splice preparation will be torn off by acceleration belt 8 Apply detection label black or aluminum Correctly position for optimum tail length Apply an aluminum detection label for postpress exit if required Release splicer brake Rotate roll to avoid dust and moisture condensation falling on to tape Set lateral position of new roll to align it with running roll to avoid the high risk of splice failure 7 A or web break OPTIMISED PAPER HANDLING amp LOGISTICS 7 At the Printer Paper onto Press Splice Pattern Straight splice preparation 1 Reflective tab 2 Direction of rot
74. overs and core plugs inspect test with Schmidt hammer Record roll number and bar code if system fitted Load roll on to splicer Remove brown wrapper weigh and dispose Slab off white waste weigh and dispose o WE Ee e p I Prepare splice Rotate roll to avoid dust falling onto tape Set cocking roller if needed to compensate uneven rolls 1 Splice cycle 8 Remove core part roll Support butt roll as chucks are retracted Automated Roll Handling System Automated roll delivery and truck unloading Scanning roll data and allocation Automated main roll store Roll preparation with weighing station Record roll number and bar code Automated daily store Load roll on to paster splicer incl splice cycle eS qe SI Sd Q0 D I Remove core part roll waste disposal Source KBA Splice Preparation Tool Kit 1 Schmidt hammer to test rolls for soft spots 2 Flat bladed knife for removing roll end covers 3 Roll slitter for stripping available from most paper suppliers 4 Scissors to cut off splice ears 5 Sharp knife with undamaged blade for cutting out damage store in scabbard when not in use 6 Sandpaper or powered sanding disc to smooth out damaged areas of the roll 7 Tape squeegee applicator 8 Good lighting where rolls are inspected and prepared for splicing 9 Roll report sheet for monitoring paper data and splice web break failures 10 Tapes and tabs need to be stored at 10 40 C 50 104 F with 40 6
75. p Sheet Source www ideaexchange sappi com Optimise press performance by conditioning paper and board to pressroom conditions and keeping it wrapped until it is required to be used 7 At the Printer Paper onto Press Climate and Sheet Paper Edge Problems Dimension variations Paper fibres will either absorb or exude moisture depending on RH causing them to swell or to shrink particularly in the cross direction of the paper rather than in the machine direction A 10 change in RH causes paper to grow 0 1 to 0 2 across the width which will cause printing mis register Humidity and curling Curling is closely connected to fluctuations in humidity that cause the paper fibres to expand and shrink in the cross direction If paper is moistened on one side the fibres expand in one direction causing the paper to curl toward the dry side As soon as a balance in humidity within the paper structure has been restored the effect is cancelled out Stack humidity and temperature on ink drying A high humidity balance of the paper stack can significantly extend ink drying times The effect is pronounced above 60 RH leading to drying times up to three times as long as normal Extended drying times can also occur when the stack of printed paper is too cold See also Modules 1 3 and 7 Edge Problems Wavy edges Usually caused when paper is exposed to an increase in relative humidity and the edges absorb moisture and expand while th
76. per adjustment or malfunction of paster carriage SESS ES ESSE ESSE ESSI ES ESSE ESSEUSS XS SS ES SS PS 26 Roll runs off core S 21 Incorrect brake load tension setting SS 28 No low tension make ready setting start up break 29 Press stops in splice cycle no web break but no splice SS 30 Press speed change during paste cycle 31 Oscilation of compensating roller pumping 32 Erratic tension near end of roll 33 Excessive tension during splice SS SS SS BSSLESS 34 Brakes fail to transfer correctly v 35 Air supply failure cause loss of tension SS SS BSSLISS SS PS DS 36 Drops of oil water ink falling on to web s 37 Overpacked blanket explodes splice in printing unit 38 Zero speed splicer head rollers out of alignment s 39 Faulty zero speed dancer operation see page 26 OPTIMISED PAPER HANDLING amp LOGISTICS 7 At the Printer Paper onto Press Paper Roll Repairs piri E ATE i I 1 Loose and bad winding Adjust web tension tight less Edge damage Slab down the part maximum 3 cm 1 3 tight Stick tape around a roller in the paper path at of roll diameter Control roll end surface to edge cuts the web edges to increase diameter to centre the web Separate rolls from the same winding position Change to another roll winding position or different roll batch The recommendations on these pages are from Paper First Aid published by the ERA
77. per onto Press Roll Changing amp Splicing Devices Two techniques are used either manual unwinders that require the press to be stopped for five minutes or longer to change the roll or automatic roll changing and splicing at full press speed for continuous production There are many variations of technologies and functions for both Unwinders An expanding shaft supports the roll by its core as itis unwound The press has to be stopped to manually changeover the roll and to join the expiring web on to the new roll with glue or tape Some models allow a second roll to be mounted for more rapid changeover This technique has A high performance automated unwinder can handle largely disappeared from many web applications except for some narrow width web presses web rolls up to 1370 mm 54 0 weighing 1500 kg at and for digital presses for speeds below 150 m min 500 fpm because of their low investment maximum speed up to 300 m min 1000 fpm for web f widths of 203 752 mm 8 30 Source Hunkeler cost The use of larger diameter rolls can reduce the frequency of roll changes by 30 40 unwinder maximum roll diameters range from 000 to 1370 mm See page 20 for best practices when using expanding roll shafts Digital Printing amp Butt Splicing Many digital presses use A4 A3 cut size paper while high volume presses use rolls ranging in width from 200 to 840 mm Most inkjet printing systems prefer butt splices to reduce the spli
78. r Rail Road Ship Source Hapag Lloyd A IMPORTANT SAFETY NOTICE A general guide cannot take into account the specificity of all products procedures laws and regulations We therefore recommend that this guide be used only as a complement to information from suppliers whose safety operating and maintenance procedures along with applicable local legal regulations always take precedence over this guide Always check machine is in its specified safe position before working on any component e g with compressed air electrical power and gas disconnected Only trained maintenance personnel adhering to safety regulations should perform maintenance work Best Practice A Safety 2 x Poor Practice Environmental amp Economic Impact CONTENTS PAPER STORAGE Bulk Paper Warehouses Printers Paper Store GENERAL STOREAGE REQUIREMENTS 4 Climate Variables 4 Building 5 For Loading Ramps Circulation amp Aisles Markings amp Working Safely Materials Reception Dispatch Lighting Fire Safety Electric Truck Maintenance amp Charging Station WAREHOUSE OPERATIONS 10 Safety amp Security 10 Fire Precautions 10 Hot Work 11 Battery C 11 Loading Ramps n Good Housekeeping PAPER STACKING 3 Paper Delivery Procedures Roll Storage Patterns Part Rolls Polls Guards Stacking Heights Paper Pallets CONTENTS SECURING PAPER LOADS FOR TRANSPORT Cargo securing Fo
79. rces acting on a load Securing cargo units Stowage loads notes Lashing and securing material ROAD TRANSPORT ua Inspection of cargo spaces Road transportation issues Forces and acceleration Cargo securing ig and Securing of Rolls amp Pallets Dangers during road transportation RAIL TRANSPORT Inspection of railway wagons Loading Unloading lashing and securing Rail Transport Handling Damage mE TRANSPORT CONTAINERS Container suitability Planning I 7 Inspecting the container Protection of cargo Loading m Securing WATER TRANSPORT Container carriers Lolo Lift on Liftoff OHGC and box shaped vessels STORO and side port ships General cargo vessels OPTIMISED PAPER HANDLING amp LOGISTICS Barges OPTIMISED PAPER HANDLING amp LOGISTICS apping amp Pallets 1 Paper amp Cores Wrapping amp Pallets IMPORTANT SAFETY NOTICE A general guide cannot take into account the specificity of all products procedures laws and regulations We therefore recommend that this guide be used only as a complement to information from suppliers whose safety operating and maintenance procedures along with applicable local legal regulations always take precedence over this guide Always check machine is in its specified safe position before working on any component e g with compressed air electrical power and gas disconnected Only trained maintenance personnel adherin
80. recyclable should be placed in the general industrial waste stream OPTIMISED PAPER HANDLING amp LOGISTICS 7 At the Printer Paper onto Press Unprinted coated amp WFC Unprinted white newspaper Old newspapers amp magazines Old corrugated containers Mixed papers 0 20 40 60 80 100 m Price 96 This table shows the relative value of different types of paper collected for recycling Prices increases with whiteness and paper fibre quality Source Standard EN 643 2013 for Paper and Board for Recycling The revision of European standard EN 643 2013 coincides with a fundamental change in waste legislation The Waste Framework Directive introduces a procedure for defining End of Waste criteria that a given waste stream need to fulfil in order to cease to be waste The End of Waste criteria require compliance with EN 643 the provision of information on material that has ceased to be waste and the implementation of a quality management system EN 643 defines what the 95 different grades of paper for recycling may or may not contain It facilitates trading and establishes comparable requirements for a material traded inside and outside of Europe It defines this material as natural fibre based paper and board suitable for recycling consisting of paper and board in any shape or product made predominantly from paper and board which may include other constituents that cannot be removed by dry sorting such as coatings laminates sp
81. rmation either manually most paper mills provide peel off i labels that can be stuck onto a report sheet or automatically using barcode into a data log or Br a Electronic Data Interchange EDI This provides essential data on paper use and allows rolls to 70706 860 60 0 be traced in the event of paper problems Radio frequency RF tags are a roll tracking technique used by some mills and printers The 126 00731 873 tag is inserted into the roll core and can be automatically read by detectors in the store on lift s trucks roll transporting devices and at splicers to give the status of all rolls in the plant at all 158 100 times Api i a Read bar code or peel off label 3 Load Roll onto Splicer Source WOCG icmPrint Best Practice and Safety First Before operating the paster all staff must know the manufacturer s safety regulations and operating instructions A Arm rotation safety Before splicing and during manual arm rotation the operator must verify that rotation path is clear of personnel and foreign objects A Emergency stop devices All staff must know their location and function Unwrapped roll ends Some paper rolls are marked with inkjet on the ends with roll number weight unwind direction mill splice position These markings help ensure that the roll is loaded onto the splicer with the correct unwind direction and marks any mill joins to allow detection a
82. roll handling and loading Publication gravure web widths of 2450 to 3680 mm are common and the widest rolls are 4320 mm Logistics need to be adapted to handle and store rolls at the paper mill in transit and at the printer The threshold for roll handling automation is from 2 2 tonnes it can be lower using either rail or AGV systems Key automation issues for safety and productivity e Auto unwrapping needs standardised roll packaging e Auto splice preparation needs multi function splice tape Paper needs to be in acceptable temperature RH range Most new high speed presses use automated roll handling located in an area secured with safety fencing and access protection around the splicer Automatic rool Stripping and weighting station loading onto the Roll transport to the daily store by forklift AGV The tipping station tilts the roll horizontally and sets it on the Patras trolley EE T i i ul v disposal station iy E m ES Xd rw E 2 Roll transport to main store by ABB E clamp AGV I T Roll transport from goods Automatic emptying of the waste reel A IN g 3 DEEIS mem We reception by clamp AGV with barcode scanning and individual reel allocation Automated offloading from delivery trucks Ls Y High productivity press installations have increased automation for multiple process steps Source KBA OPTIMISED PAPER HANDLING amp LOGISTICS
83. s at splicing C Transfer to nip roller Re check alignment of web and ensure it is square and of uniform tension X ifthe paper is stiff or has a curl away from the nip roll it may be necessary to roll the material so that it conforms to the curvature of the nip roller X Itis essential that any uncovered holes in the vacuum bar are sealed off with tape otherwise a failed splice may occur x Any build up of tape or paper on nip rolls may prevent a good seal at time of splice Remove the complete protection strip liner from the adhesive Clean off any excess adhesive from the prep bar D Close the splice head Rotate the nip roller in the direction that the web will be running until it is taut Splice failure web break paper waste press downtime folder jam Splice failure poor adhesion Trouble shooting zero speed dancer operation Web break during Deceleration Dancer cylinder ports closed Chain sprockets worn Dancer brake malfunction Web break during Splice Insufficient air pressure Web break during Acceleration Dancer rollers out of alignment Dancer bottoms out Inadequate air pressure on dancer Inadequate acceleration signal air flow volume or electric Leaking dancer cylinders Dancer not at maximum position before splice runs out of paper Dirty or glazed acceleration roller Loose dirty or worn acceleration belt Dancer does not fill prior to splice Dancer tension too low Brakes set too tight Air leak
84. to Press Troubleshooting amp Maintenance It is essential that the manufacturer s preventative maintenance procedures are completely followed to ensure optimum performance safety and reliability and to enhance equipment life Substitution of recommended consumable parts drive belts brake pads foam rollers should be done with caution to ensure these alternatives have the same specifications and performance Core Troubleshooting When in doubt contact core supplier to access correct parameters Usually the printer does not know the core supplier and therefore should contact their paper supplier Poor torque transmission Core chew out at winder or printing press 1 Clean chucks 2 Checkif chucks are worn including internal parts 3 Checktolerance between core inside diameter and cylindrical part of chucks Compressed oval core and roll Check roll truck clamp pressure and handling See Modules 4 and 5 Roll bounces heavily in unwinding Possibly some smoke and burnt smell 1 Checkif roll is out of round before looking for a core issue 2 Checkthe chuck length and chuck expansion is working correctly 3 Compare specified roll weight is dynamic strength too low Residual roll vibrates during unwinding near the splice Core and paper has too low critical speed in printing press 1 Checkthe press supplier requirement for E modulus of the core and core density relation Decrease printing speed Splice at a larg
85. ucks Some Specifications ROLL CLAMPING Contact Pads Clamping Force Lift Truck Capacity ROLLTRUCKS O S Lift Mast Mountings Hydraulic Requirements Troubleshooting OTHER HANDLING EQUIPMENT Recycled Paper Waste Palletized Paper 1 At the Printer Paper onto Press A IMPORTANT SAFETY NOTICE A general guide cannot take into account the specificity of all products procedures laws and regulations We therefore recommend that this guide be used only as a complement to information from suppliers whose safety operating and maintenance procedures along with applicable local legal regulations always take precedence over this guide Always check machine is in its specified safe position before working on any component e g with compressed air electrical power and gas disconnected Only trained maintenance personnel adhering to safety regulations should perform maintenance work CONTENTS 2 FUNDAMENTAL PAPER CONDITIONS FOR PRINTERS Optimise Temperature amp Humidity Paper Rolls Sheetfed Paper Issues Static charge INTERNAL LOGISTICS FOR PRINTERS Paper Delivery Inspection Storage Paper Handling ROLL PROCESSING EFFICIENCY Web Breaks Splice Faults and Web Breaks Roll Changing amp Splicing Devices Roll Cores Splicing Tapes and Tabs Web Tension a Key to Efficiency Preparing the Roll for Splicing Roll to Web Processing Steps Flying Spl
86. uctors can dissipate static when net gt au Noncon s insulators such as plastic and wood have rons can not mov onductivity of th lulose iber whi in ie surface c t Ther vi ihn uH large format gl meo ae e can be of lar challenge because the ultra smooth si contact al weight and body Sinci PLA E st x ducti best a co ted charges ud iot dissipa nta iit conductor and sparks a discharge T IIS Cause amp Effects of Static Electricity in Paper Sappi e Do not unwrap paper until printing is about to start Avoid storing paper close to hot or cold Technical Tip Sheet la un heat sources Source www ideaexchange sappi com OPTIMISED PAPER HANDLING amp LOGISTICS 7 At the Printer Paper onto Press Separate And Recycle Waste Around 4096 of paper is made from collected waste paper and board that is turned into recycled pulp Waste paper is the urban forest and a key resource of the sustainable economy By collecting separating and selling their waste some printers cover the cost of their monthly ink bills To manage this resource effectively e Separate waste to measure its volume maximise its recycled value minimise both actual waste volume and the cost of any residual disposal by incineration or landfill e Dispose of contaminated packaging materials by following the rules for the product that polluted it e Discuss with recycling companies government agencies or others to
87. xperience of the printer virgin fibre mixed or recycled paper The following table is a guideline example only start up tension settings e nfi hu T ne l oGl MIU J ALLIT vidi SLAI up OHUN 40 120 gsm 120 150 N m 0 6 8 8 6 pli Paster Paster 70 90 N m __ pli Infeed 30 60gsm gsmx10x909 N m Infeed 200N m pli 60 90 gm ___gsmx10x80 N m 90 120 gsm gsmx10x709 N m 7 N m 0 00571 pli pounds linear inch 1 Always reset tension when changing paper weight 2 Set low start up tension level to minimise risk of web break at low speed 3 Fine tune tension during makeready and running 4 Record settings for each paper and web width for faster future set up with less waste Too high tension causes wrinkles increased web break risk and can change print length Too low tensions causes web wander Half and Part Roll Widths Part roll widths generally run better in the centre if the folder permits For twin web in line configurations the half web should be run in the lower position to print in the second set of units to avoid running a part web over air turns and to minimise tension variations Some zero speed splicers use parallel festoon rollers A Most splicers use tapered rollers to self centre the web and provide better tension on web edges B If the roll cannot be run in the centre for some 2 web productions the rollers will need to be taped to avoid web wander C The dancer r

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