How To Transform Web Handling Challenges Into Operational Wins

September 11, 2024 | 4 min read

In industries that rely on continuous roll-to-roll processing, effective management of web handling machinery is crucial for maintaining efficiency and quality. Key challenges such as tension variability, wrinkling, and equipment downtime can compromise product quality and disrupt operations. 

To address these issues, modern web handling systems incorporate technological innovations like automation and real-time data integration, which enhance control over tension, speed, and web alignment. 

Designing web handling systems requires careful consideration of material properties and environmental conditions to ensure optimal performance. Additionally, preventive maintenance and reliability engineering are essential for minimizing unexpected downtimes and ensuring safe, efficient operations. 

Precision Roll Solutions (PRS) excels in delivering tailored machinery solutions that integrate these advanced features, transforming complex challenges into opportunities for operational triumphs. In this article, we explore how PRS’s expertise in engineering and equipment customization drives success across a range of industries.

Tackling Web Handling Pain Points Head-On

Industry veterans know that success often hangs by a thread — or more accurately, by a web. Professionals across industries face constant pressure from equipment limitations, unexpected downtime, and quality issues. These hurdles can affect everything from production efficiency to final product quality. Understanding and addressing these common concerns is key to achieving operational excellence:

  • Unexpected downtime: Aging, breakdown-prone equipment can cause production waste, delays and missed deadlines.
  • Quality inconsistencies: Variations in tension control, roll alignment, or surface finish can end up compromising product quality.
  • Capacity constraints: As production demands increase or new products are introduced, existing machinery may be unable to meet the need.
  • Space limitations: Increasing production capacity or capabilities can be especially challenging when a facility’s footprint cannot be expanded.
  • Technological gaps: Legacy equipment often lacks modern control systems, automation, or safety features.

PRS specializes in addressing these pain points with customized solutions that optimize web handling processes, boost productivity, and enhance product quality.

When Web Handling Excellence Demands Tailored Solutions

1. Custom-Engineered Converting Equipment

PRS offers a comprehensive range of customizable converting equipment designed to meet the exacting needs of industries such as paper, plastics, metals, pharmaceutical, building materials and consumer products. Our solutions include:

Precision Roll Solutions’ machinery can be customized for specific applications, such as matched steel embossers, perf embossers, rubber-to-steel embossers, paper-to-steel embossers, nested embossers.

Our experts also recognize that customers often need more than off-the-shelf equipment to solve their specific challenges. That’s where robust technical expertise and the ability to customize equipment can make all the difference.

2. Retrofitting and Upgrades: Breathe New Life into Existing Machinery

Maximizing ROI on equipment investments often relies on extending the life of current machinery. Not all equipment providers have the industry experience or time on the production floor to understand the nuances of integrating new systems and capabilities with legacy equipment. Our experts regularly retrofit and integrate:

  • Advanced control systems for improved precision and automation
  • Enhanced safety features to meet modern standards
  • Upgraded drive systems for better speed control and energy efficiency
  • Improved web tension control mechanisms for consistent product quality

3. Intuitive Operator Controls & Effective Diagnostics Alarming

When selecting a solution provider for web handling processes, integrating advanced technology is essential to staying competitive and maximizing efficiency. Look for experts who can help you integrate the latest technologies to modernize and enhance production lines, such as:

  • Advanced sensors and real-time monitoring systems that enable proactive maintenance by detecting potential issues early, thereby reducing downtime and extending equipment life
  • Modern control systems that can adjust operations in real-time based on changing conditions, enhancing efficiency and product quality
  • IoT integration for comprehensive data analytics and remote monitoring, which can improve decision-making by providing insights into production processes and enable remote management and troubleshooting

Partner with a provider skilled in technological integrations to keep your operations at the forefront of industry advancements.

Transforming Operations with Customized Equipment Solutions

When it comes to customizing equipment for web manufacturing processes, the right solutions can lead to significant improvements in operational efficiency and product quality. Here are some potential outcomes achievable through effective equipment customization:

Enhancing Product Quality and Reducing Downtime

In industries like paper production, where quality inconsistencies and web breaks are common challenges, modernizing equipment can yield substantial benefits. Implementing advanced tension control mechanisms, precision-engineered rollers with specialized coatings, and integrated real-time monitoring systems can result in:

  • Fewer web breaks: More consistent tension control reduces the likelihood of web breaks, leading to smoother operations and less downtime
  • Improved product quality: Precision controls and custom components can help ensure more uniform product output, to meet higher quality standards
  • Increased production speeds: Optimized systems can handle higher speeds without compromising quality, boosting overall production efficiency

Partner with PRS for Your Web Handling Success

At Precision Roll Solutions, we understand that every web handling challenge is unique. Our team of experienced engineers works closely with you to:

  1. Analyze your specific operational needs and constraints
  2. Develop customized solutions to effectively and efficiently address your challenges 
  3. Implement upgrades to help minimize disruption to your operations
  4. Provide ongoing support and optimization services, including aftermarket support for parts, technical service and training

Whether your challenge involves maximizing the lifespan or enhancing the safety of aging equipment, boosting production capacity, or integrating technological advances into your web handling processes, PRS has the expertise and solutions to drive your success.

Ready to transform your web handling challenges into operational triumphs? Contact Precision Roll Solutions today for a consultation, and let's engineer your path to improved productivity and enhanced product quality.
Written by Jeff Taylor and Kent Kohls

Jeff Taylor - Vice President of Business Development – Converting Equipment

Jeff’s more than 30 years of experience in the paper and converting industry began in field service and winder start-ups, and progressed through project management, technical sales, and leadership roles before starting his own business — which he ran for 25 years before joining the PRS team.

As VP of Business Development for Converting Equipment, Jeff connects customers with the right machinery for their needs. He analyzes requirements and recommends optimal equipment solutions, collaborating with customers as a technical problem-solving partner.

Jeff is driven by the challenge of solving complex customer challenges through innovative approaches. He enjoys the flexibility to develop creative solutions that address unique issues and solve production problems. His extensive industry knowledge and experience, from operational details to strategic planning, enable him to transform tough challenges into opportunities.

Whether analyzing equipment configurations or devising new approaches to customer problems, Jeff applies his technical expertise and passion for the industry to every project he undertakes at PRS.

Kent Kohls - Director of Engineering, Machinery Center of Excellence

Kent holds a bachelor of science in mechanical engineering from Marquette University and brings 33 years of web handling machinery experience to PRS. His career spans several industry sectors, including five years designing diaper machines, five years in paper industry project management, and 17 years in custom converting machinery as a project and engineering manager.

As Director of Engineering, Kent oversees all aspects of the design and build process for custom web handling machinery at PRS. He oversees projects from design to completion once an order is placed, and also provides technical expertise during the final stages of the sales process to ensure customer requirements are fully understood and can be met by the PRS team.

Kent’s expertise covers a wide range of industries, including consumer products, building materials, pharmaceuticals, renewable energy, and metals. He appreciates the diverse challenges presented by different industries, products, and processes, noting that if a product can be made in a web format, PRS has likely built a machine for it.

His extensive experience across multiple industries enables Kent to lead the engineering team in developing innovative custom machinery solutions that meet the unique web handling needs of PRS customers.

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