Converting machines rely on precise applicator rolls to ensure proper glue application and lamination of tissue products. Rolls that are out of tolerance or have excessive variation cause poor adhesion, wet/dry spots, scrap, and customer complaints.

A converting facility was struggling with product exhibiting poor adhesion, wet/dry spots, scrap, and customer complaints. These issues began immediately after the installation of a new rubber-covered applicator roll.

Although the roll was technically meeting the specified tolerance, the roll was ground with a 0.003" taper that was using almost all of the allowable gap tolerance for a glue application. The taper in the roll was creating high and low spots across the sheet, leading to inconsistent lamination, unsellable product and escalating scrap.

The facility worked with its grinding partner to re-evaluate and tighten roll specifications and to eliminate the taper relative to the machine’s operating gap. The new set of rolls was ground to a much tighter tolerance, ensuring consistent glue application across the width of the machine.

Inconsistent lamination and wet/dry spots were removed, scrap related to this issue was eliminated, the facility restored product quality, and eliminated the source of customer complaints.

Even when rolls fall within “acceptable” tolerances, the relationship between roll geometry and machine operating gaps must be considered. In this case, tightening tolerances and eliminating taper relative to a narrow glue gap ensured consistent lamination and provided significant savings.

Contact us to be connected with your local account manager to learn more.