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THEARTOF

WINDING

GOOD ROLLS

By R. Duane SmithProduct Manager

Specialty Winding

DAVIS STANDARD CONVERTING SYSTEMS

Fulton, New York 13069

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THE ART OF WINDING GOOD ROLLSBy R. Duane Smith

Product Manager - Specialty WindingDavis Standard Converting Systems

Fulton, New York

ABSTRACT

Every web manufacturer and converter is faced with the challenge of winding quality rolls of

their high quality products. This paper provides definition of a quality roll of paper, film or

nonwoven material. The reader is made aware of the importance of the control of in-woundtension to consistently produce good quality rolls. It discusses the winding principles used on

all winders to control in-wound tension or roll hardness. Then the basic types of center,surface and combination center/surface winders will be compared with the advantages anddisadvantages of each. After the discussion of how roll hardness is achieved, methods of

measuring roll hardness are presented. Finally, roll defects to avoid in producing quality rolls

of web materials will be listed and the book "Roll and Web Defect Terminology" will bebrought to the audience's attention for them to learn more about the causes and cures of

common roll and web defects.

NOTE- This paper deals primarily with the winding of paper and nonwoven web materials.Please refer to the article The Challenges of Winding Flexible Packing Films which can be

found at www.bc-egan.comunder Converting Systems/Company Information/Publications

and Tech Documents or www.bc-egan.com/public_html/Company/publications.html.

INTRODUCTION

If all web materials were perfect, then the ability to produce perfect rolls of these productswouldnt be much of a challenge. Unfortunately due to the natural variation in resins and

additives and non-uniformities of the film formation processes, there is no such animal as a

perfect web. The winding operations challenge is to wind webs with slight imperfections

being sure that these slight imperfections do not stand out in appearance and are notamplified during the winding process. Then it is the responsibility of the winder operator to

make sure that the winding process does not produce additional variations in the product

quality. The ultimate challenge is to wind a web product with slight imperfections andproduce quality rolls that will run on your customers process without problems and produce

high quality products for their customers.

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DEFINITION OF A QUALITY ROLL

If the challenge is to wind quality rolls, then the first task is to define our customers

definitions of good quality. A baker will tell you that in order to please their customers, they

must produce rolls that are of the right shape, the right size, the right consistency not toohard and not too soft, they must look good no blemishes or visual defects, and they must

have a good aroma. A film product customer wants rolls of film that are:

The right shape

The right sizeThe right consistency

Must look good

Aroma?

- Round and proper width

- Right diameter or length- Proper roll density not too hard or soft

- No blemished or visual defects

- Well, start shipping your customers badrolls of film and they are going to raise

a stink!!!

Your customers demand a roll that will run without problems. Most will tell you that, if aroll of material looks and feels good, then it will run without problems. It is a well known

fact that you cant improve the quality of paper or other products on the slitter winder. Still,

it is every winder operators job to insure that the web defects are not amplified or madeworse during the slitting and rewinding operation. The purpose of this paper will be to

discuss the factors that go into the consistent production of top quality rolls off a slitting and

rewinding operation. This article will be centered on roll hardness and visual defects andhow they can be controlled for consistently rewinding good rolls. (Smith, 2001)

ROLL HARDNESS

Roll density or hardness is probably the most important factor in determining the difference

between a good and bad roll. Rolls that are wound too soft will have slippage of the layers

when they are unwound at higher tensions, commonly know as cinching. This layerslippage will cause roll defects such as starring and/or telescoping unless they are unwound

at very light tensions. Rolls that are wound too soft can also go out of round while winding

or will go out of round when they are handled or stored. The roundness of rolls is very

important in your customers operation. When unwinding out of round rolls, each revolutionwill produce a tight and slack tension wave. These tension variations can distort the web and

cause register variations in the process. The only way to minimize the affect of these tension

variations is to run the operation at a much lower speed, which greatly affects the productionrates.

Rolls that are wound too tight will also cause problems. Tightly wound rolls contain highinwound tension. These rolls can split open like a watermelon when dropped or squeezed by

a roll handling truck. The web will stretch and deform as these stresses are relieved as the

roll cures during storage. If this inwound tension becomes too high, bursts can occur insidethe wound roll. (See Photo #1) These cross machine tension bursts are normally well hidden

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and can not be detected until the roll is unwound. These bursts cause web breaks which

cause major production losses on your customers production lines.

Photo #1: Cross Machine Tension Burst

Since there is no such thing as a perfect web, it is the responsibility of the winder operator tomake sure that these slight imperfections do not stand out in appearance and do not cause

their customers process problems. Rolls that are wound too tightly will exaggerate web

defects. No web is perfectly flat or the same thickness from one side to the other. Typicallywebs will have slight high and low areas in the cross machine profile where the web is

thicker or thinner. If the rolls are wound too hard then the web will stretch over these thickerareas causing bumps or ridges. (See Photo #2A) As the web is stretched over these ridges, it

deforms in these areas. This causes untensioned areas in the web, known as baggy areas,

when the roll is unwound. (See Photo #2B) There may also be moisture streaks where theweb is higher in moisture in localized areas across the web. These moisture bands will cause

web defects know as corrugations, or rope marks, in rolls which are wound too tight. (See

Photo #2C) Ridges and corrugations cause the customer process problems such as poorregistration on a printing line.

These slight defects will not be noticeable in a wound roll if sufficient air is wound into the

roll in the low or wet areas and the web is not stretched over the high areas. Still, the rollsmust be wound hard enough that they will be round and will stay that way during handling

and storage.

Some webs, either by their formation process or by their coating or web conditioning

process, have cross machine variations of thickness or moisture too severe to be wound

without exaggerating these defects. To overcome this, these webs are moved back and forth

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before they are slit. This process, called oscillation, which randomizes these localized

defects across the wound rolls. On a slitter winder, the unwind is normally oscillated.Oscillation may be either a constant speed, stop and constant speed back or a sine-type wave

speed curve. What is important is that the oscillation speed is fast enough to randomize

defects and slow enough that it does not strain or wrinkle the web and that the rolls after they

have been slit are wound with straight edges. The rule of thumb for the maximum oscillationspeed is 1 per minute per 500 feet per minute winding speed. For best results, the

oscillation speed should vary proportional to the winding speed.

Photo #2A: Ridges in a Roll Photo #2B: Baggy Web

Photo #2 C: Corrugations or Rope Marks

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How to Achieve and Measure Roll Hardness

Now we know why roll hardness is important. Next lets discuss how to achieve and

measure roll hardness. As a roll of web material winds, tension builds inside the roll which

is known as inwound tension or residual stress. If these stresses become greater as the roll is

wound, then the inner wraps towards the core will loosen. This is what causes the rolls todish while winding or telescope when they are handled or when they are being unwound in

your customers production operation. To prevent this, the rolls want to be wound tight at

the core and then wound with less tightness as the roll builds in diameter as shown in Chart#1. The larger the finished rewind diameters, the more critical the roll hardness profile is.

Roll Hardness vs. Diameter

0

20

40

60

80

100

120

Diameter

Hardness

Taper

Ideal Hardness Taper

Maximum Hardness Taper

Minimum Hardness Taper

Core Full Roll

Note- Hardness Number is a relative number and will depend on device used to measure the hardness.

Chart #1: Roll Hardness versus Diameter

Roll hardness is developed in different ways on different types of winders but the basicprinciples of how to build roll hardness are always the same. To remember these principles,

just remember that to consistently wind Dynamite Rolls you need T.N.T. (Seidel, 1987)

T ension - The Winding Web TensionN ip - The Nip of the Pressure Roll or Drum

T orque - From the Center Drive or Torque Drum

The three basic types of winders are:

1. Surface Winders2. Center Winders3. Center/Surface Winders

Each type of winder uses one of more of these T.N.T. winding principles to build wound roll

hardness. We will now describe each of these winder types and compare the advantages anddisadvantages of each.

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SINGLE DRUM SURFACE WINDERS

The Single Drum Surface Winders are the simplest and least expensive type of winders. As

shown in Figure #1, these will use Web Tension and Nip. Because of the amount of wrapthat is normally around the driven winder drum, web tension is isolated from the winding

roll. On non-extensible products such as heavy board, web tension has little effect on roll

hardness. Basically, roll hardness is affected only by the control of the nip pressure. Onextensible products such as extensible films and nonwovens, roll hardness is controlledthrough both web tension and nip.

Figure #1: Surface Type Winder

The advantage of this type of surface winder is that the rolls weight does not affect theamount of nip load. The disadvantage is that the Single Drum Surface Winder has limited

control of roll density and must be a shafted operation. A single drum winder requires much

less horsepower than a center winder and is normally used on as a continuous type winder forheavier grade products and extensible nonwovens.

Two Drum Surface Winders

Two Drum Surface Winders are normally used for stop/start slitting and rewinding

operations and use all three principles for maximum control of roll hardness. See Figure #2.

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Figure #2: Two Drum Surface Winders

This type of winder normally has sufficient wrap on the drum so the web tension has littleeffect on the roll hardness when winding non-extensible grades. Roll hardness and profileare achieved by programmed nip control of the rider roll pressure and programmed torque

control from the torque drum. Today, these winders are normally shaftless operations and

are high speed and very productive. The disadvantage is that this type of winder typicallybuilds hard rolls as the winding rolls weight produces the winding nip. This requires highrider roll pressure at the start which is relieved proportional to the winding rolls weight as it

winds. Programmed torque control is the most effective tool in controlling roll hardness

which also requires a hard nip to transmit the torque into the roll without slippage.

Two Drum Surface Winders are used as high speed slitter rewinders for light density grades

such as nonwovens or heavier paper, board or laminate grades that can tolerate being woundhard.

Single and Dual Drum surface winders are:

Best for winding hard rolls (i.e. protective films) Best utilization of space and horsepower Best for winding very large diameter rolls Best for minimizing waste during transfers Less expensive Less equipment Single & smaller winding drive

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Pure Center Winders

Pure Center Winders use web tension or, when combined with a pressure roll, can use nip

and web tension to control roll hardness as shown below. Please note that on this type of

winder, torque produces web tension. See Figure #3.

Figure #3: Single Position Pure Center Type Winder

A Pure Center Winder may be single position or continuous operation turret winder andmay be a shafted or shaftless operation. (See Figure #4) Often this type of winder

provides flexibility of gap or contact winding to control amount of air being wound into

roll and roll hardness.

Figure #4: Continuous Pure Center Type Winder with Nip Roll

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Pure Center Winders have the ability to wind softer rolls than a Single Drum Winder and

have better in-wound tension control. Still they only use one or two of the principles tocontrol roll hardness.

Pure Center Winders are normally used on lighter grades which are wound at lighter

tensions and to smaller roll diameters. They require much higher horsepower thanSurface Winders as the tension horsepower needs to be multiplied by the ratio of the

maximum speed at core to the maximum speed at full roll to obtain the horsepower

required at the full roll.

An advantage of center winding is that this process can wind softer rolls. This type of

winder on a continuous process line can provide quick indexing and fast cycle times. Thedisadvantage of center winding of film is the limitation of maximum roll diameter due to

the torque applied through the layers of web material. Also, center winders have a higher

probability of generating scrap during roll changes.

Pure center winders are: Best for winding soft rolls (i.e. web materials with gauge bands) Best for winding web materials with high tack Best for winding small diameter rolls Easily designed for dual direction winding Able to provide adhesiveless transfers

Center/Surface Winders

The Center/Surface type winders uses all three principles in controlling roll hardness and

may either be configured in a continuous turret type winder or a center/surface single shaftsimplex or dual shaft duplex type slitter winder. The surface drive produces the web

tension while the nip pressure of the pressure roll and the torque from the spindle driveproduces the roll hardness. See Figure #5.

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Figure #5: Continuous Center/Surface Turret Winder

By programming these nips and torques, the desired roll hardness and profile can be

achieved. The nip can be controlled independent of the rolls weight. The disadvantage ofwinders of this type is the cost, complexity, & lower production due to the shafts required

when slitting and rewinding. See Figures #6A and 6B.

Figure #6A:Simplex Center/

Surface RewinderFigure #6B:Duplex Center/Surface

Rewinder

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Measuring Roll Hardness

The setting and programming of the tension, nip and torque to produce the desired roll

hardness will vary depending on:

a) The type and design of the winder

b) The type of web material being woundc) Width of the rolls being woundd) The speed of the winding operation

Different web products and different applications for these products will dictate the roll

hardness desired. Once the desired roll hardness profile is determined, it needs to be

measured and then reproduced on a consistent basis. The measurement tools need to be handheld and available on the winder so an operator can check roll hardness being obtained and

make adjustments accordingly to insure that the roll hardness is within the acceptable range

for that product.

To measure the roll hardness across the outer surface of the roll, it is suggested that either aRhometer or a PAROtester be used. Both of these are impact based devices for measuring

relative roll hardness on a relative scale. The Rhometer is an instrument that measures thepeak deceleration of a small hammer as it strikes the outer surface of the roll. (See Photo #3)

The PAROtester is similar to the Schmidt hammer. The Schmidt Hammer was developed for

concrete hardness testing and has been borrowed for use of roll hardness testing. ThePAROtester has been developed specifically for evaluation of hardness of rolled-up paper,

foils and films. The PAROtester is considerably more sensitive, has less impact energy and is

less operator dependant due to its more defined direction of impact then the Schmidthammer. (See Photo #4)

Hardness Devices for Measuring Roll Hardness across a Roll (Roisum, 1988)

Photo #3: Rhometer Photo #4: PAROtester

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A Smith meter is an instrument that can be used to measure the hardness profile from the

core to the outer wraps of the roll. The Smith meter measures the penetration of a smallneedle as it is inserted in the wraps of the web along the rolls sides. (See Photo #5)

With the computerized data acquisition systems now available such as the Black Clawson

AccuWind systems, it is now possible to calculate the Roll Density Factor (RDF) and plot therelative roll density from core to full roll as the roll winds. These systems compare the actual

winding rolls diameter with the theoretical diameter and plot the ratio as a function of the

winding rolls diameter. The RDF is displayed to the operator on the Operator InterfaceTerminal (OIT) at the winder as shown in Photo #6.

The operator needs to have a means to measure the roll hardness from both core to full rolland across the roll available on the winder.

Hardness Devices for Measuring Roll Hardness from Core to Full Roll (Roisum, 1988)

Photo #5: Smith Needle Photo #6: AccuWind Roll Density Curve

ROLL DEFECTS

So far, we have concentrated on the importance of roll hardness and how it is produced and

measured. We have discussed roll defects that are caused by roll hardness which are:

Out of Round Rolls

Internal Web Bursts Ridges

Baggy Paper

Corrugations or Rope Marks

Now lets turn to other visual defects that need to be avoided in order to consistently wind

good rolls. These defects include:

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Poor Starts

Core Offsets

Splices

Offsets and Interweaving

Dished and Telescoped Rolls

Starred Rolls Trim Wound In Rolls

Slitter Rings

Other Slitter Defects such as:Excessive Slitter Dust

Nicked Blades

Scalloped Edges

High Edges

Poor Starts

Poor starts are defined when there are

obvious differences in appearance betweenthe paper near the core and the remainder of

the roll. See Photo #7.

Causes of Poor Starts:a) Starting to wind with slack in the webb) Web wrinkling at the start of the windc) Poor quality coresd) Loose winding near the core

Poor Start Remedies:

a) Tighten web before fastening to coreb) Start with web straight on cores

Photo #7: Poor Startc) Use good quality, properly stored cores

d) Start with proper tension, nip and/or

torque

Core Offsets

Core offsets is defined when the coresextend inside or out of the sides of the rolls.

See Photo #8.

Causes of Core Defects:a) Cores not aligned with slit websb) Web not securely fastened to the core

Core Slips Remedies:

a) Be sure cores are aligned with slitters

b) Securely retain cores and fasten webs securely tothe cores

Photo #8: Core Offset

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Splices

Splices in a roll are necessary

evils. Splices are normally due to

web breaks or cutting out

defective material in a parent roll.Most customers will allow up to 3

splices in a roll of wound material

but will not allow rolls withsplices near the core or near the

full roll. They also insist that

splices be properly made andproperly marked. Bad rolls

contain numerous splices or

poorly made splices or containunmarked splices. See Photo #9.

Causes of Splices:

a) Poor product in parent roll

Photo #9: Poor Spliceb) Web breaks

Splice Remedies:a) Reduce bad material in parent roll to a minimumb) Determine if web breaks are due to defects in material or winder and correct problem

Offsets and Interweaving

Offsets are defined as an abrupt change in the

position of the edge of the web.

Causes of offsets:

a) Shifts in the core shaft or coresb) Oscillation speed too fastc) Quick change in web tensiond) Quick change in nip loade) Web slippage inside of the roll

Offset Remedies:a) Be sure that core shaft and cores are

securely retained

b) Check oscillation speed relative to webspeed or binding in oscillation mechanism

Photo #10: Web Offsetsc) Correct abrupt changes in speed or tensiond) Check for binding or other reasons for abrupt changes in nip loade) Do not increase Tension, Nip or Torque during the winding operation

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Interweaving is often caused by severe offsets in the rolls that are wound side by side on awinder. In addition to the above causes, interweaving may also be caused by improper

spreader device adjustment, too low of winding tension, or uneven cross machine web

tension.

Dished and Telescoped Rolls

Dished rolls are defined as rolls which

are wound with progressive edge

misalignment that may be convex orconcave. Dished rolls are ones that this

curvature occurs while the rolls are

winding. Telescoped rolls are rolls thatthis curvature occurs while handling or

unwinding the rolls of web material. See

Photo #11.

Causes of Roll Dishing:

a) Cores that are not held stationaryduring winding

b) Winding soft and then windingtighter at the outer wraps

c) Misalignment causing the web toenter the winding roll non-parallel to

the core axisPhoto #11: Dished Roll

Remedies of Winding Dished Rolls:a) Make sure cores are firmly retained during windingb) Achieve a good, hard start at the corec) Insure the roll hardness does not increase during windingd) Check for machine misalignment

Causes of Roll Telescoping:a) Soft start of windingb) Winding a soft rollc) Unwinding at higher tension than the roll was wound

Remedies of Roll Telescoping:a) Wind tighter rolls with a good, hard start and decreasing roll hardnessb) Unwind with less tension

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Starred Rolls

Starred rolls are defined as rolls in

which the ends have a star pattern due

to the shifting of the layers of web in

localized bands starting at or near thecore and continuing out towards the

outer wraps. These localized shifts

cause a star pattern which issymmetrical but frequently one or

more rays of the star are missing. See

Photo #12.

Causes of Starred Rolls:

a) Winding Tight wraps after a rollhas been loosely wound

b) Thin web thickness on the end of aroll causing a soft edge

c) Severe impact of a wound rollPhoto #12: Starred Roll

Remedies of Starred Rolls:

a) Wind tight at the start and then gradually soften roll hardness as diameter increasesb) Keep cross caliper variation to a minimumc) Oscillate before slittingd) Provide for proper handling and transporting of rolls

Trim Wound in Rolls

Trim wound in rolls is caused when the

winder trim is not collected into the trimremoval system and follows the web

into the winding roll. See Photo #13.

Causes of Trim Wound In Rolls:

a) Insufficient air velocity at trimnozzle

b) Turbulent air flow in the trim

removal systemc) Web offsets in parent roll greater

than trim width

Photo #13: Trim Wound in Roll

Remedies of Trim Wound In Rolls:

a) Check to insure the air velocity at intake of trim removal system is greater than windingspeed

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b) Check to insure laminator air flow at trim nozzlesc) Edge guide unwinding roll or be sure that offsets are not greater than trim width

Slitter Rings

Slitter rings are defined as concentric

ring patterns on the edges of the roll thatgive the roll edge the appearance of a

target. This defect is very common on

winders with mandrel mounted bottomknives after the mandrel has been

reground on or more times. See Photo

#14.

Causes of Slitter Rings:

a) Excessive slitter run outb) Wobble of bottom knife ringsc) Poor fit of bottom knives on mandrel

Remedies of Slitter Rings:a) Insure that run out of bottom knives

after grinding does not exceed the

thickness of the websPhoto #14: Slitter Ringsb) Check to be sure that bottom knives

have a close sliding fit with mandrelc) On individually driven bottom knives, check run out of drive shafts

Other Slitter Defects

Listed below are our common roll defects caused by slitters:

a) Slitter Dust - Excessive slitter dust is caused by dull slitter blades, excessive overspeed ofbottom knifes and/or worn slitter bearings.

b) Nicked Blades - Nicked blades cause roll edges to have small and very short pieces ofweb protruding from the smooth roll edge. Nicked blades are commonly caused byengaging top blades on top of bottom knives or improper storing or handling of the slitter

knives.

c) Scalloped Edges - Scalloped edges are defined as rolls in which the slit web widthincreases and decreases during the winding process. This is normally caused by

excessive slitter run out, insufficient side pressure on shear slitters or slitters that are not

securely retained during the slitting process.

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d) High Edges - High edges are defined as a slitting defect which results in the edges of theslit rolls flared up. This defect is common when razor type slitting is used and is causedby dull razor slitters. It is corrected by replacing the razor knives or by moving the razor

to obtain a new cutting point on the blade. This defect can be minimized by oscillating

the razor blade to vary the cutting point on the blade during winding.

Properly defining all of the roll and web defects and addressing the possible causes and

remedies is far beyond the allowable pages of this article. The new book Roll and WebDefect Terminology (2

nd edition) by TAPPI PRESS describes defects commonly found in

paper, film and non-woven webs and wound rolls. (Smith, 2007)

This new and greatly improved 2nd

edition contains: Illustrations, Causes and Remedies for

224 Defects with common Synonyms for each, which are cross referenced in the Index. Thenew edition as been expanded to 10 Chapters including chapters on:

Roll Defects General Roll Defects Web Profile

Roll Defects Edge Roll and Web Defects -Wrinkling Web Defects Papermaking Web Defects Calendering Web Defects Aqueous Coating Film Extrusion and Lamination Defects Web Handling Defects Slitting Defects

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Roll and Web Defect Terminology (2nd

edition) was written and edited by 22 IndustryExperts with over 500 years of combined experience in web handling and winding plus 16

additional Contributing Editors. The new edition has been expanded to provide an

Introduction written by each Chapter Champion. These introductions include

troubleshooting, problem solving information, and flow charts. The cause and effect logicgiven in each chapter can be used to look for similar happenings in your own process, and

uncover the real reasons behind a troubling production problem.

Each chapter lists the common defects associated with the chapters topic.

The information regarding each defect includes: A description of the defect Provides an Illustration for each defect Lists the synonyms or Also Known As terms commonly used Cross references these synonyms in the Index Lists common causes of the defect

Lists the common remedies of the defect Lists other sources of information published on the defect

TAPPI newest publication, Roll and Web Defect Terminology (2nd

Edition)has already been

recognized by the web producing and converting industry experts as the most comprehensive

Reference Guide available for addressing roll and web defects. This new book is a MustHave communication toolfor Suppliers and their Customers to assist in the identification

and elimination of Roll and Web Defects.

Roll and Web Defect Terminology-2nd

edition is now available through TAPPI Press at

www.TAPPI.org/bookstore or by calling 1.800.446.9431 (US) 1.800.446.9431 (Canada) or+1.770.446.1400 (Worldwide)

In Conclusion

Winding good rolls is the challenge that every slitter winder operator faces. Consistently

winding good rolls depends on the consistency of bringing good material to the slitting and

rewinding operation. A winder operators job is not to camouflage poor quality webproducts into shippable rolls. His or her responsibility is to handle webs with slight

imperfections and to produce quality rolls that will run without problems on your customersprocess and produce high quality products for their customers. I hope that the informationpresented will help in meeting this challenge.

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References

1. Roisum, D.R., How to Measure Roll Quality, TAPPI Journal, October 1988.2. Seidel, K.L. Practical Approach to Winding Principles, TAPPI Winding Short Course,

1987.

3. Smith, R. Duane (Editor),Roll and Web Defect Terminology- 2nd

edition, TAPPI PRESS,

Atlanta, 2007.4. Smith, R. Duane. The Art of Winding Quality Rolls. Paper Film & Foil Converter, pp 46-

53, August 2001