Double unwinding system of OMET drastically reduces the time and material needed for job changeover
May 21, 2014
The innovation concerns the insertion in line of a double unwinder, a semi-automatic unwinding system for ultra-fast change of the printing substrate. With it, the operator only need to switch from one material roll to another, previously uploaded on the second shaft of the double unwinder, cut, splice and start printing.
The second unwinding shaft is an option that can applied to the printing presses of the XFlex line. The two shafts can be used alternatively so the preparation of the new roll on the free shaft could be done while the machine is still in operation.
The double unwinder helps saving several minutes in the changeover process; as a consequence the productivity and profitability of the machine increase with any type of run. Let’s make an example: with a production speed of average 120 meters per minute, the use of material rolls of 2.000 meters each and 2 8-hour job shifts a day, you can save in 1 year 321 hours of production (over a total of 230 days of machine output a year) on any OMET printing press. This means saving approximately 1090 rolls of raw material!
Overall costs are decreased of a 75 percent and the machine downtime for roll replacement is reduced to less than 1 minute – versus 3 minutes on a configuration without double unwinder when the extra time is needed to remove the core of the finished roll and upload the new one. In addition, the job change can be performed by 1 operator only as the roll replacement is carried out during production.
The double unwinding system is another step taken in the direction of the maximum operational flexibility and efficiency to reduce costs at a minimum. It is worth of note that the double unwinding system changes subtly the machine layout but does not affect the work of the operators, thus realizing the concept of the concentration of the most advanced technology in the shortest possible footprint. This promotes the careful use of factory spaces and the maximum ergonomics of movements.