[UPDATED ON APRIL 2024]
Soft nonwoven requires specific precautions in end-of-line operations to maintain the qualities obtained during the production process. In some cases, when processing particularly soft and bulky materials, we have to evaluate alternative solutions to traditional rewinding to obtain the best result.
If the goal, for example, is to produce a small-format reel containing a high number of meters of soft and sensitive nonwovens, using a standard rewinder could lead to an unsatisfactory result, obtaining a voluminous and not very dense reel compared to customer requirements.
Furthermore, when transporting large reels there are evident geometric constraints, in addition to the fact that the type of nonwoven in question can be damaged during the various handling operations.
This is why A.Celli offers, as part of the F-LINE® product range, an alternative solution to rewinding capable of preserving the softness and bulkiness of the nonwoven: Spooling.
What is Spooling
The A.Celli F-LINE® lines dedicated to spooling are based on a system capable of wrapping narrow strips of sensitive nonwoven around a shaft. Thanks to the transversal movement of this shaft it will be possible to obtain, with a process ideally similar to the winding of the yarns, a finished spool with an overall width greater than the strip itself and containing a number of meters of material higher than a standard reel, with obvious advantages in terms of productivity in the subsequent converting phase.
As regards the technical data, the spooling lines are able to process nonwovens with basis weight from 15 to 200 gsm wound in master rolls with a maximum diameter of 2000 mm and width from 350 to 1200 mm (without considering customized solutions able to manage larger formats), all at a maximum speed of 800 m/min and using up to 12 spooling heads. Thanks to a variable slitting width from 35 to 140 mm, it will be possible to obtain finished spools of soft nonwoven with a width from 400 to 850 mm and a diameter up to 1200 mm.
A spooling line ideally comprises three sections: unwinding, slitting and actual spooling. Therefore, starting from the jumbo roll, we obtain a number of nonwoven strips equal, at most, to the number of spooling heads and of reduced width, which will subsequently be wound around the winding shaft. In order to obtain a correct winding of the product in object, the tension is carefully controlled at each stage of the winding process and the single strip is duly positioned to produce finished spools characterized by a flat surface.
The main technical features of Spooling
Let's see, in the table below, a summary of the technical details of Spooling:
|
|
Spooling |
|
Strip width / slitting width (mm) |
35 - 140 |
|
Finished product shape |
Reel |
|
Finished product dimensions (mm) |
Width: 850 Diameter: 1250 |
|
Tension control |
Yes |
|
Max. operating speed (m/min) |
800 |
|
Density |
High |
If you want to know more about soft materials handling, download our free eBook "How to manage soft Nonwoven and bulky Tissue paper".
