You’ve already optimized a section of your line hoping to increase capacity, but then begin experiencing a bottleneck or slow down of subsequent segments. To resolve these unintended consequences, the entirety of the web handling process should be evaluated to determine where improvements must be made.
The evaluation starts with an understanding of all current control systems and process capabilities, new technology potential, and the different characteristics of the product as it feeds through the machine. Then, using advanced process control modeling, solutions can be designed to mitigate control speed differentials that accrue at different sections. The result is to maximize the efficiency of paper manufacturing without causing unforeseen issues further down the line.
Motor and coordinated drive systems should be selected and designed for each section based on normal running load (NRL) and recommended drive capacity (RDC) calculations. Sectional motors load-sharing capabilities also contribute to determining the power required to account for speed differentials in other sections.
Control systems must monitor, process, and respond to operating condition variations in each section. Removing slowdowns and bottlenecks to the winder is critical to optimize performance. High speeds, adjusting motion control, precision tension, and efficient control communication are necessary capabilities. These allow for rapid, dynamic changes to speed and torque while ensuring the product is unwound from parent rolls, slit, trimmed, and rewound without damage.