Solutions for the Winding of

Nonwovens

2014
David Roisum, Ph.D. INDA 2014
Finishing Technologies, Inc. 80.1
 What is a Web?
Long Thin Flexible

All webs follow the same laws of physics

If we know the physics, we know the behavior 80.2
 What Is Web Handling?
Web Handling Wrinkling
Rollers (3) Wrinkle Cause/Cure
Tension Control (2) Spreading
Web Converting
Nip Control (2)
Slitting
Temperature/Moisture Winding
Effects and Control
Guiding (Path Control)
Other
Material Properties
Physical Properties
Problem Solving 80.3
 Why Study Web-Handling?
Baggy Webs
Curl
Length & Width (dimension)
Registration (location)
Web Breaks
Winding Defects
Wrinkling
etc
80.4
 Why a Nonwovens Focus?
Material Properties are quite different
Low modulus (favors different defects)
Rough surface (no air entrainment)
Looser web/machine tolerances
Your cousins are tissue
Winding
Different defect set
Different winder settings
Different quality measure
80.5
 Winders are Found in
Web-to-roll (Slitter) Rewinder
Manufacturing such as Cut large master rolls into smaller
Paper machine diameter and/or smaller width shipping
Film extrusion rolls
Foil mill
Textile loom
etc
Roll-to-roll
Converting at high speeds such as
Calendering
Coating Salvage (Rewinder)
Laminating Some roll defects can be fixed by
Metallizing rewinding
Printing
etc Offsets, telescope, soft rolls
Offline roll-to-roll process used where Also, edit/splice out web defects
inline is to restrictive or too unreliable Invaluable for trials and product
Roll changes may be automated and inspection
made at speed to keep process running
Flying splice unwind, winder turret,
accumulator

Winding enables Web Handling 80.6

 Winder Classes - # Knobs
Knobs to adjust Wound
Center Wind
Roll Tightness
Tension

Web Tension

M1
Nip Center Wind w
Layon Roller
Ni p

Centerwind Torque Tension

differential

M1
Ni p
Surface Wind
s - some products are Tension

speed dependent (due

M2
Ni p
to air entrainment) Center- Surface
Wind Tension
Known at the TNTs ( M1+ M2)

M2

M1
of winding Centerwind Torq. Diff.
80.7
( M1-M2)
 Winder Classes - Range
Tightness

Centerwind range is Loose Tight

Center Wind
from min to max web Tension

tension

1
M
Nip

Layon roll nip adds Center Wind w

Layon Roller
Tension

additional tightness

1
M
Nip

Surface wind cant get Surface Wind

Tension

as loose because of

2
M
Nip
required nip Center-Surface
WindTension
?

Center-Surface has
(M1+ M2)
2

1
M

widest range Centerwind Torq.

Diff.
80.8
 Winder Type - Turret
Continuous production winder
Wind one spindle, index over to new spindle
Wide range of products and processes
Index Core(shaft) support
Layon Roller Turret Large rolls a challenge
Center, Center w Layon
n s f er or Center-Surface class
d t r a ho w n
n
a
Cut No
tS Spindle A Spindle B or Gap

Turret Mech 80.9

 Winder Type - Reel
Continuous production winder
Start on primary, move to secondary arm
Follows almost every paper machine
Primary Arm Core(shaft) support
Secondary Arm
Upsets at bottom of roll
Index
Surface wind class

Reel Mech 80.10

 Winder Type Duplex
Offline slitter-rewinder
Duplex: wind every other roll wound Inboard Roll Out board Roll
on opposite side of drum or machine
Extreme Application Range
Converting: small narrow rolls w/o
spreading
Paper Mills: $20M magazine grades Drum

View
From
Top

80.11
Duplex Mech
 Winder Type Two* Drum
Offline slitter-rewinder
*Optional 3rd roller known as Rider Roller
Mostly paper, rubber and textiles
Rider Roller Shaftess or Shafted
Surface wind class
Wound Roll
Very Durable
Very Productive
Drums
Two Drum Mech
Programmed Nip 80.12
 TNTs and Tightness
Tension: makes roll tighter
Nip: makes roll tighter, Tension

especially soft materials or

Ni p
smooth materials at high
speeds
Torque diff: makes roll
tighter (or looser)
s: makes the roll tighter
(when you slow down)
M2 M1
Centerwind Torq. Diff ( M1-M2) 80.13
 TNTs add up to WIT
Wound-In-Tension is the tension in the
current outer layer of the roll WIT

Tension + Wound Roll:

Nip + WIT + WIT,
Torque Mat erial tight ness,
propert ies hardness,
Stresses, etc 80.14
 TNTs > Same Tightness
If TENSION is giving If NIP is giving you
you trouble, lower it trouble, lower it and
and RAISE NIP in its RAISE TENSION in
place its place

If you need to tighten, raise both

If you need to loosen, loosen both
Nip most effective with compressible materials80.15
Nip and Compressible Materials
WIT is a result of Nip is extremely effective
for bulky materials such
interlayer slippage as nonwovens, textiles
under the nip and tissue
Nip tightening requires
a pad of soft material to
Non-uniform slippage work
can cause defects Thus, the layers just
above the core are a bit
looser than elsewhere
Thus, the possible
justification for center-
surface winding 80.16
 Programmed Nip
Roll Structure
What > Automatically

Nip Cylinder Pressure

Tight Start
vary nip pressure as a Looser Finish

function of current

Core

Outside
diameter ( Current ) Roll Diameter

Why Geometry Compensation Swinging Arm Wgt

Nip Cylinder Pressure

Structure a roll
Compensate for geometry
Compensate for gravity

Core

Outside
( Current ) Roll Diameter Variable Mech. Advantage

All of the above Nip Cylinder Pressure

Roll Weight Compensat ion Rider Roller

How Roll Wgt

Cam Drum Nip

PLC
Core

Outside
( Current ) Roll Diameter
Calculation
80.17
Lookup table
 Nip Calibration Example
Here is a modern two-
drum with two gross
calibration oversights 30
Actual
Zero was offset by 7.8

Rider Roller Nip ( PLI)

Actual
PLI on tissue! 20
Hysteresis
P
(uncertainty) was ro
gr
greater than the range 10 am
me 22.9
of the fancy roll d 7.8

structure computer
program being run 10 20 30 40
Current Roll Diamet er ( in)
80.18
 How Tight to Wind the Roll?
Baby Bear Theory:

Not too tight to damage web

Not too loose to allow roll damage

80.19
 Defects and Tightness
Loose Defects > Tight Defects >
Damage Roll Damage Web
Flat spots Blocking
Out-of-Round Core Crush*
Telescoping Corrugations
Etc. Gage Bands > Bag
Tin Canning, etc.
Defects Not affected by Tightness
Offset core
Wrong roll width Tight and Loose Defects 80.20
 Wound Roll Structure

T,N, T or WIT
What
Tight Start
Smooth Transition
Looser Finish Core Outside
Current Roll Diameter
How
Taper any of the TNTs
Why: reduce defects due to
Roll Handling
Starring
Telescoping

80.21
Radial Stress or Pressure
ZD Radial St resses Pressure is highest
-Interlayer Pressure
at core
Without taper,
pressure is
10 Int erlayer Pressure roughly level
0 through most of
Radial Stress (psi)

-10 10 Roll
20 Roll
30 Roll
40 Roll
the roll
-20 S-shaped pattern is
-30 Outside
the trend common
Core

-40
to most winding
0 5 10 15
Radial Position (in)
20 25 situations

80.22
 Width Will Be Nonuniform
Physics allows only three solutions
Wind under zero tension
Variable width slitting
(variable width when unwound)
Saw cut roll (variable web
width when unwound)

80.23
 Bulk (Thickness) Loss
Interlayer pressure can cause a loss of bulk
(thickness, caliper etc) if the product creeps (with
time) under those loads
Permanent losses can vary from less than 5% on
a newsprint reel to more than 50% on finished
rolls of tender nonwovens More durable material
Lower winding tightness
Pressure

Caliper
OD

OD
Core

Core
Position Position 80.24
 Bulk Loss and Core Support
Pressure over the
Core Support Pressure

core/mandrel can
cause bulk loss
Which source of
pressure is bigger?
Calculation (very Winding Pressure
difficult)
Compare losses of
size and full size rolls
wound under same
tension
80.25
 Telescoping Case IA - Initial
Winding core
supported roll
Roll begins wind OK

80.26
 Telescoping Case IA - Latter
Winding core
supported roll
Roll begins to shift
Latter part of winding

26.27
Telescoping Case IA - Appearance
Winding core supported roll
When
It Slipped
Where
It Slipped

Min Safe Core Dia

For given condit ions

Max Safe OD
For given Core et c
80.28
 Telescope Case IA - Remedies
Winding -Maximum taper (especially tension)
Product Re-Design
Change Web
Increase web-web friction for torque induced
Increase density for nip induced
Core diameter increase
Roll diameter decrease Max

Operational

Max Slip Zone

WIT

Radius
Sideguards
Living with waste Min

Diameter

OD
Core

80.29
 Telescoping Case IV
More formally known as Progressive Outward Dishing
During Winding (most commonly a 2 Drum)
Multiple rolls wound on same axis grow in width due to
Interlayer pressure and
Poisson effect
Diagnostics
No J-line motion needed
Rolls wider above core than at outside
Progressive outward roll edge pattern
Remedies
Winding Minimum winding tightness (T, N and T)
Increase spreading of multiple rolls wound same axis
Web or roll product design 80.30
 Rough Roll Edge - Other
Nip friction >
sawtooth edge
Web Vibration >
feathery edge
Machine Vibration >
feathery or corduroy
Unslit edges
Trim jump
Slitter Rings
80.31
 Rough Roll Edge Tree
Simple tests can determine which branch
of the troubleshooting tree you are on
Web Moved
Of f set
Wr ap Rol l Moved
Ro ug h
Ro l l Edge Tensi on,
Wr ap
Wi dt h Var Sl i t t er Moved

Wri nkl e at Sl t r
80.32
 Winding With Gage Variation
Winding Unwinding

The size of the diameter variation that might do this could be as little as 1/1,000
The web gage variation that caused this diameter variation could easily be below the
threshold of ordinary web measurements and controls
Roisum, David R. The Secrets of a Level Process and Product. Various venues, 2001.
80.33
 Corrugation Description
A.K.A. Ropes, Chain Marks, Tin Can
Narrow annular band, wrinkles at an angle
Caused by Winding
A caliper-varying product
Tight, especially with nip

80.34
Corrugation Mechanics
Web
Gage
Profile

Wound
Roll
Diamet er
Profile

Out er layers in wound

roll shear and collapse
int o hollow
Large diameter Small diameter
slowed down by nip sped up by nip
against roller against roller
80.35
 Ridges (and Valleys)
You dont need a lab test or scanner to
know this web has gage variation issues

80.36
 Buckles and Stars - Mechanics
What
Known as buckles, stars, wagon wheel
and spokes
Seen as wavy layers and/or spokes on
the end(s) of a roll
Caused by layers buckling due to MD
compression like earthquake faults
Observe
Symmetry of (angle between) points
Symmetric natural
Asymmetric unnatural often a blow
or squeeze due to handling
Symmetry of one end versus other
Symmetric symmetric gage
Asymmetric starred end is the low
gage side
80.37
 Buckle and Stars - Types
Poor Roll Structure

Tightness
OD tighter than ID
Tight over loose but
Collapse over unsupported
layers
Roll offset/dish/telescope Core Outside
Core inset Current Roll Diameter
Core collapse
Gage Variation Air Buckles
Intentional Wound-in entrained air escapes
Coating short of edges Smooth low gage materials
Unintentional High speed
Rough handling 1 hr to 1 day
Asymmetric pattern
Blow
Squeeze
80.38
 Paro Roll (Hardness) Tester
Instrumented version of a billy club

80.39
 (Overall) Roll Density
Measure Wound Roll Density

80.40
 Winding Books
Roll and Web Defect Terminology by Duane
Smith 1995, 2007
Winding Machines, Mechanics and
Measurements Dr Keith Good and Dr David
Roisum 2007
Winding by Ken Frye 1990
The Mechanics of Winding by David Roisum
1994
Winders the Complete Guide by Jan Gronewold
1998.
Anthology of Winding by Jan Gronewold 2000

TAPPI PRESS, tappi.org, (770) 446-1400

80.41
 Questions?

Answers:
David Roisum, Ph.D.

http://www.webhandlingblog.com/
http://www.roisum.com
drroisum@aol.com
920-725-7671 office
920-312-8466 cell
80.42