Problems and Solutions
Die-Cutting
Problem:
We use a web Die-Cutting Press to process materials made of resilient paper and plastic. We are unhappy with our current Die Cutting Press because of electrical problems, processing speed, and cracking edge guides. What equipment do we need?
CONTECHs Solution:
Switch to a CONTECH Web-Fed Die-Cutting Press Systems. The Web-Fed Die-Cutting Press can hold the closest tolerances while still maintaining speed and quality. Aluminum edge guides would be added to prevent cracking, and the control unit could be mounted on a swing arm for easy operator use.
Problem:
What do you do when your dies are getting torn up, costing you $1,500 each to replace, and you don’t have three days to wait for new dies? We work with a sponge material that has to be die-cut. The material occasionally has stray metal particles that break the dies.
CONTECHs Solution:
Change to a CONTECH UltraPress. It is able to thermal die-cut, emboss, steel-rule kiss-cut, and most importantly steel-rule die-cut. A steel-rule die can be replaced or created in-house, significantly reducing cost and down-time.
Problem:
We are a custom screen-printing and Custom Die-Cutting Press operation, and were having problems with holding close tolerances, excessive wear on dies, and uneven die-cuts on our clamshell and econocut-type presses. What kind of machine do we need?
CONTECH’s Solution:
The Ultrapress from CONTECH was designed for problems such as those. Adjustable stop-blocks on each corner ensure that cutting pressure is spread evenly across the surface, eliminating both uneven cuts and damage to dies. In addition, the X, Y, and Theta registration allows the table to move rather than the die, allowing the press to hold a very tight tolerance in registration and depth.
Sheeting/Slitting
Problem:
We are sheeting material consisting of aluminum and polymers to specific widths and lengths by hand. What equipment do we need to speed this up?
CONTECH’s Solution:
The CompuSheeter is microprocessor controlled for sheeting quickly with precise accuracy. The CompuSheeter is also versatile, capable of processing just about any kind of material. For faster speeds, the ServoSheeter is capable of speeds up to 300 feet per minute depending on the increment. Both the ServoSheeter and CompuSheeter are reliable and easy to use and can also be equipped with optional slitters for razor, score, or shear slitting.
Problem:
We must hold tolerances of + .015 and + .020 for material that is 48 to 80 in length. The equipment needed must also be custom designed to match our production specifications. What do you suggest?
CONTECH’s Solution:
The CONTECH ServoSheeter. The ServoSheeter can be custom designed to match any production specifications. The ServoSheeter is fast and versatile, capable of sheeting a variety of materials while still holding tight tolerances. The ServoSheeter includes a drive system which is duty-rated for 24 hour, 7 days a week operation
Problem:
How do you convert and package light and pressure sensitive material from rolls to sheets when you can only stack the sheets three inches high?
CONTECH’s Solution:
Manufacture two machines.
#1 Sheeter / Slitter Slits and sheets the material, then place the material in the trays of a cart.
#2 Packager: Takes the material off of the trays of the cart, places the material sheet-by-sheet into the shipping box, with foam slip-sheets in-between each piece of material for protection.
Problem:
What equipment can sheet material to the close tolerance specifications of an automated manufacturing system, yet is still able to operate 24 hours a day?
CONTECH’s Solution:
Use a CONTECH ServoSheeter to sheet the material with a tolerance of up to ± .020. The ServoSheeter is also designed using a Servo drive mechanism instead of an electric motor, thus it is 24 hour a day, 7 days a week duty rated.
Sheeting/Stacking
Problem:
What equipment do we need to sheet and stack a thin, composite polyethylene film with an embossed pattern, yet still be able to use the machine for other materials and operate continuously?
CONTECH’s Solution:
Sheet and stack the nonwoven material with a CONTECH Sheeter/Stacker equipped with multiple unwinds for continuous operation. The Sheeter/Stacker is able to process many different types of materials at close tolerances. In addition, the system can be custom designed with equipment including an automated loading conveyor for ease of use.
Problem:
We need to convert a new non-woven material from rolls to sheets, but were having problems with static and stacking the material.
CONTECH’s Solution:
Several solutions are available. One is to invest in a Sheeter/Stacker from CONTECH; Sheeter/Stackers can be custom designed to handle your nonwoven material, cut to the desired tolerances, and stack the material, all at very high speeds. To handle static the web can be equipped with a hot bar or metallic tensile to remove static, or the area can be flooded with ionized air.
Problem:
How can we die-cut and kiss-cut a material that is so gummy that it adheres to the dies, making it impossible to knock the product out?
CONTECHs Solution:
Custom design a CONTECH UltraPress with a talcing device attached to the in-feed, and a œdouble knock-out that will punch the product above the die into a chamber. Air can then be pumped through the chamber to clear the product onto a conveyor belt for collection.
Slitting/Rewinding
Problem:
We are planning to add a product line to our existing line of custom-made non-woven paper products. How can I slit non-woven material narrowly then rewind it while still maintaining quick turn around?
CONTECHs Solution:
Custom design a Magna S/R Slitter Rewinder. The score slitting Magna S/R is extremely fast and is capable of slitting a variety of materials. The Magna S/R has available options of razor and shear slitting, and web guiding for precision accuracy.
Problem:
We are trying to improve efficiency in cutting different types of padding and linings made of cotton polyester and nylon. Presently we are doing this manually by hand. What kind of machine would speed this process?
CONTECHs Solution:
Custom design a CONTECH system which would include a CONTECH EconoSheeter and a roll unwind system. The EconoSheeter is an air operated scissor shear sheeter equipped with electronic controls. The roll unwind can be designed to handle various weights and diameters of roll materials. It is a simple and economical system.