Rotoflex Sales Playbook - Words Have Impact · Rotoflex Sales Playbook 1.1. The Rotoflex Story...

2011

The Rotoflex team

Mark Andy Inc.

6/4/2011

Rotoflex Sales Playbook

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1. An Introduction to Rotoflex ............................................................ 1

1.1. The Rotoflex Story ................................................................... 1

1.2. What Rotoflex Does ................................................................. 2

1.2.1. What is Offline Finishing?.................................................. 2

1.2.2. Making Labels is a 2-step Processes ................................ 2

1.2.3. Inspection .......................................................................... 3

1.2.4. Slitting ............................................................................... 3

1.2.5. Rewinding ......................................................................... 4

1.3. Finished rolls need to be soft and straight ............................... 4

1.3.1. End Users Want Consistent Soft Rolls .............................. 4

1.3.2. Good Tension Control Produces Straight Rolls ................. 4

1.4. Applications ............................................................................. 4

2. Rotoflex Overview .......................................................................... 7

2.1. Rotoflex Models Overview ....................................................... 7

2.2. The Benefits of a Rotoflex Solution .......................................... 8

2.3. Genesis Advanced Control System ......................................... 9

2.3.1. Value added .................................................................... 10

2.3.2. The Control Screen ......................................................... 12

2.3.3. Using Genesis for Counting ............................................ 12

2.3.4. Using Genesis to Catch Faults ........................................ 14

2.3.5. Four Genesis levels ........................................................ 15

2.4. eDrive Technology ................................................................. 18

2.4.1. Value added .................................................................... 19

3. Inspection .................................................................................... 20

3.1. The LT-Vision System ........................................................... 20

CONTENTS

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3.1.1. Value added .................................................................... 20

3.1.2. The Tube Light System ................................................... 21

3.2. VSI: Compact Inspection/ Slitting/ Rewinding ........................ 23

3.3. VLI: Advanced Inspection/ Slitting/ Rewinding ....................... 26

3.4. DSI: Inspection/Slitting with Die Cutting ................................. 31

3.5. Options .................................................................................. 34

3.5.1. Common Options for Roll Inspection/Counting ............... 34

3.5.2. Common Options for Slitting ........................................... 34

3.5.3. Common Options for Rewinding and Unwinding ............. 36

4. Selling Rotoflex ............................................................................ 38

4.1. The Sales Process ................................................................. 38

4.1.1. Phase I – Identify and Qualify an Opportunity ................. 38

4.1.2. Phase II – Finding and Presenting a Solution ................. 40

4.1.3. Phase III – Quote and Formal Proposal .......................... 41

4.1.4. Phase IV – Close and Build Implementation ................... 45

4.2. Competitive Response ........................................................... 45

4.2.1. AB Graphics .................................................................... 46

4.2.2. Prati ................................................................................. 47

4.2.3. Rotocontrol ...................................................................... 48

4.2.4. Local Builders .................................................................. 49

5. Service Information ...................................................................... 51

6. Appendices .................................................................................. 52

6.1. Rotoflex Options Summary .................................................... 52

6.2. Application Worksheet ........................................................... 60

6.3. Validation Questionnaire ........................................................ 60

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1.1. The Rotoflex Story

Rotoflex was initially established in 1973 as a maker of rotary tooling.

Soon after, the company began making converting equipment for the

label printing industry, pioneering the first machine designed

specifically for vertical inspection, slitting, and rewinding. Since then,

Rotoflex has established itself as the industry standard in inspection

and rewinding equipment. The brand offers solutions for virtually any

application in any market, from blank die-cutting to the most

sophisticated inspection requirements.

In 2008, Mark Andy Inc. acquired Rotoflex International. Rotoflex was

already a well-established name in finishing products, globally

respected for its innovations in the industry. As part of Mark Andy Inc.,

Rotoflex joined a family of global leaders in printing press offerings.

Together, Rotoflex and Mark Andy are well-equipped to provide

complete workflow solutions for the converter.

Since the acquisition of Rotoflex,

Mark Andy Inc. has placed an

emphasis on technology and

design enhancements. These

enhancements include integration

of the eDrive system into the

entire product line as well as the

superior advantages of the

Genesis advanced control system.

Rotoflex continues to push the

envelope in finishing systems, with

more than 4500 installations

worldwide. By investing heavily in

research and development, Mark

Andy Inc. is committed to pro-

viding complete workflow solutions

to converters around the world.

1. AN INTRODUCTION TO ROTOFLEX

1. Rotoflex VSI

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1.2. What Rotoflex Does

Rotoflex machines provide a number of quality offline finishing

solutions for label printers worldwide.

1.2.1. What is Offline Finishing?

―Finishing‖ refers to any process that occurs after a printing piece has

been printed on a press, and before a printed product is sent to the

customer. Such processes can include cutting, folding, binding,

packaging, and especially quality control. For label printing, finishing

includes such critical steps as slitting, rewinding, and inspection.

Originally, such finishing steps were done directly on the printing press

itself. Presses had ―add on‖ equipment that would do the slitting, for

example. Quality control was difficult with such systems, but customer

expectations were lower.

So what changed? First, presses became faster, so the need for

precision equipment and control of the finishing process became

greater. Second, the range of label materials being used on presses

began to grow. This drove the need for lower tension winders and

greater precision, especially with web presses. Third, customers

began to place more and more emphasis on quality finished rolls.

These three changes drove the growth of off-line finishing: performing

finishing steps separately instead of directly on the press itself.

1.2.2. Making Labels is a 2-step Processes

The most common and effective way to produce roll labels is a two-

step process. The first step is to print and die cut the labels, roll-to-roll,

as wide as possible and at maximum speeds. The labels are then

wound into full rolls, marking the rolls with flags where acknowledged

areas of waste are present. The second step is to then take these full

rolls to a second piece of equipment and perform the final quality

control and finishing functions, preparing the roll for final shipment to

the customer.

We at Rotoflex takes pride in our ability to effectively control all the

variables that come into play in this second step. We aim for accuracy,

consistency and a finished product that supersedes customer

expectations.

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Following is a brief overview of the three major components of offline

finishing - inspection, slitting and rewinding.

1.2.3. Inspection

Quality control is one of the most critical functions to be performed on

offline finishing equipment because, it is the last time the product is

seen before shipment to the customer. The quality of the product at

this point will reflect the quality of the label supplier to his customer.

Quality control steps can include visual

inspection and/or electronic detection.

In a visual inspection system, either a

stroboscope or a web video system is

used to freeze the printed image so

that an operator is able to assess the

print quality of the labels and remove

any bad product before it reaches the

customer. The operator can also be

assisted by electronic detection systems which will automatically detect

faults such as missing labels or improperly stripped waste matrix, flags

introduced by the press operator, millsplices and even incorrectly

printed bar codes, to make the quality control operation easier to

perform.

Defective material is easily removed, after detection, at a splicing table.

1.2.4. Slitting

After removal of all defective material, the web edge is guided in order

to slit the streams of product to fit customer requirements. For

example, a wide roll can be slit into a number of smaller rolls to obtain

the number of labels per roll and the size of roll that the customer

desires. The type of material to be slit dictates the type of slitting

device to be used.

Brush-up: A stroboscope is an instrument used to make a cyclically moving object (like a repeating roll of labels) appear to be slow-moving, or stationary.

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1.2.5. Rewinding

Due to the growing number of materials that labels are printed on,

rewinding has also become an art in itself. Each material has its own

characteristics and requires a different rewind tension. Rewinding is

especially important as the finished rolls need the appropriate tension

and profiles to complete the finished look for the customer as label

buyers have become more demanding about the specific roll

characteristics.

1.3. Finished rolls need to be soft and straight

1.3.1. End Users Want Consistent Soft Rolls

Converters must be able to provide low tension, ―soft‖ rolls to

customers. The eDrive web handling system, offered on all Rotoflex

models, can consistently deliver the soft rolls end users required.

Finished rolls are ready to box, which avoids time-wasting rewinding

on a table winder. In addition, advanced inspection and counting

ensures rolls are accurate!

1.3.2. Good Tension Control Produces Straight Rolls

Good dynamic tension control is the key to producing straight rolls.

The tension control that the A/C flux vector motor control provides

helps guarantee that the roll will be straight from core to final label.

Furthermore, rolls stay straight even with rapid acceleration and

deceleration times, and with unknown start/stop times.

1.4. Applications

Rotoflex converters continue to push the boundaries when it comes to

packaging design and production. Specific applications may be

included to make their customers' package stand out in a crowd. We

are proud to support these applications, both common and uncommon,

with high-quality equipment and service. Our engineers and product

development specialists work continuously to create new ways to

incorporate these processes into our existing product lines.

Primary Pressure Sensitive Labels

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Primary Labels are generally promotional, and are usually designed to

enhance the clients product, and raise its appearance in a memorable

and attractive way, these are usually custom designed and produced in

accordance with detailed brand specifications.

Film Labels

Film labels are primarily used for consumer packaging and promotional

materials and are always printed on a film or film pressure sensitive

substrates such as PP, BOPP, PET and PETG. Film labels generally

need equipment designed to handle the special needs of film

materials. While film labels are usually custom designed and printed

with UV inks for best results, some film label material can also be

printed water based using hot air drying.

Secondary Labels

Secondary Labels are considered to be information providing, such as

bar codes, instructions for use or safety, sequential numbering or

security data. Secondary labels often require an element of variable

print and this is normally achieved by way of direct thermal or thermal

transfer technology, however ink-jet or xerography can also be

employed.

Variable Data Labels

Variable data printing can be integrated into most of our printing and

converting solutions. Integration for ink jets and other printing

equipment can provided..

Film-Unsupported

Unsupported films are used for a variety of packaging applications,

generally beverage packaging. Bottle wraps, stretch wrap, and shrink

wrap packaging types are all produced with unsupported film materials.

Flexible Packaging

Flexible packaging includes applications such as bags, pouches and

wrappers. Often produced on mid and wide-web printing equipment,

accurate tension control and high throughput are key drivers for

finishing in this space.

Foil

Foils are used in a variety of closures and seal tops for many different

types of product packaging, such as food cups, pharmaceutical seals,

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blister packs, candy wraps and many more. A variety of aluminum foils,

foil papers and foil laminations fall into these types of printed

applications.

Specialty

Specialty printing includes a range of in-line produced items from RFID

to gaming and lottery to medical and surgical to tamper resisitant to

printed electronics, and many other possibilities in between.

Carton

Cartons are small to medium sized boxes printed and converted from

paperboard. They comprise of a significant portion of the packaging in

the retail and pharmaceutical sectors. Cartons meet packaging needs

by providing product protection, visual impact, product information and

brand identification in an efficient and easily distributed format.

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2.1. Rotoflex Models Overview

For quick reference, the following chart outlines the five Rotoflex

models currently available.

Model Target Markets

VSI – Basic rewinding,

slitting and inspection. Well

suited to label converters

and developing markets

handling standard label

materials. Also ideal for short

run inspection/ rewinding.

Standard label

converters,

converters in

emerging markets

VLI – Advanced rewinding

slitting system, available in a

greater range of web widths.

Capable of higher speeds

and handling more delicate

materials.

Narrow-web

converters, mid-

web converters,

un-supported film

DSI – Combination die-

cutting and slitting/rewinding.

Well suiting for label

converters who want to

support customers with blank

label orders, while still

expanding inspection

capacity.

Label converters,

blank label

producers

2. ROTOFLEX OVERVIEW

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2.2. The Benefits of a Rotoflex Solution

There are several benefits to using a Rotoflex machine in an offline

finishing process.

• A Rotoflex Delivers The Best Product to the End User. With

our unmatched defect detection and quality management

systems, there are fewer defects, making for a better quality end

product.

• A Rotoflex Produces Consistently Wound, High Quality

Rolls. We are an industry leader in tension management and

web handling. Our innovations lead to better control for the

producer, and rolls that are easier to work with for the end user.

• A Rotoflex is Optimized for the Operator. Each machine has

a single interface for inspection, counting, and motion control.

• A Rotoflex Allows Precision slitting. Our machines are

designed with efficient and accurate slitting in mind.

• Our company Delivers the Right Solution. We have

extensive knowledge of printing and finishing processes and

can address a wide range of customer applications and needs.

Brush-up: Tension is a measure of how “tightly” a roll of paper or labels is rolled. Too much or too little tension can lead to printing mistakes or unusable labels.

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2.3. Genesis Advanced Control System

Exclusive to the Rotoflex product line, Genesis is an intuitive, flexible

control system developed by Rotoflex engineers. With a simple HMI,

operators can monitor all functions and clearly identify faults and

issues from a single screen.

Integration of the system into

multiple machines on the

production floor allows operators

to easily transfer from one machine to another without relearning the

intricacies of a new control system. In addition to operator benefits, the

converter receives the benefits of increased productivity and revenue.

With faster acceleration and deceleration, overall cycle times are

shortened, and with recallable job recipes, repeat jobs can be run with

virtually no setup time. The system is compatible and easily integrated

with a variety of vision and detection systems.

Brush up HMI is short for Human Machine Interface.

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Final roll quality is not lost on the Genesis system. With the most

sophisticated missing label and matrix detection on the market, this

advanced system can detect missing labels in multiple lanes as well as

detect the presence of a matrix. With multi-lane counting the converter

receives accurate label counts for each roll and its capability to count

and inspect a variety of label shapes - not just squares or rectangles,

you get an accurate count of labels per lane, regardless of varying

label shapes or lengths.

2.3.1. Value added

Ease of Use

With the Genesis system, operators can

monitor all functions from a single touch

screen display. Faults and issues can be

indentified quickly and clearly.

Reduced training time required for new operators

Because the Genesis system is easy to use, there is less training time

for new operators. And because all functions can be handled from a

single screen, there is no need to learn new controls for each function

independently. This means that a lower skill level is required to

operate the machines, and fewer chances for beginner errors.

Improved Flexibility in Finishing

Operators are less likely to be tied to a single machine; once trained on

the Genesis system, operators can go where needed.

Increased revenue through increased productivity

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Using a Genesis system leads to faster acceleration and deceleration,

which means faster overall cycle times. Time is also saved during the

roll stop and roll start cycle. Though the time saved is measured in

seconds, these seconds can add up to hours of time saved annually.

The Genesis system also gives the operator more control over the

inspection process. As a result, less time is spent on defects and

errors, and the final result is a higher quality roll.

Less Time Spent Setting Up New Jobs

Starting new jobs is quick and easy in the Genesis system. The Auto-

setup feature calibrates the machine to the job, doing away with

manual adjustment. The software also allows operators to save and

store job recipes for recall later on. This means the operators can

quickly recall all critical parameters for a job—useful for repeat orders

and standard products.

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2.3.2. The Control Screen

The control screen collects key information and displays it on a single

screen:

For example, the control screen can give the operator precise readings of tension read-out, machine speed, roll count, total count, and MMLD defects.

2.3.3. Using Genesis for Counting

Accurate counts are crucial for a superior finished product. The

Genesis system can keep track of:

Linear Count: multiples of

10‖, 12‖, 10 CM.

Butt Cut Count: The

number of labels based on

the label length captured

either through Auto Setup

or entered manually.

The Auto Setup feature allows for the automatic sensor calibrations and label repeat length detection using a variable web sampling distance for waste reduction.

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Gated Count: For maximum accuracy detecting the presence of

a label by opening an electronic window and detecting leading

or trailing edge of each label. In case of clear on clear label with

a print, the label presence is confirmed by detecting the print on

a label.

Multi Lane Count: This mode allows counting of labels in

multiple label lanes regardless of shapes and repeats of the

labels in each lane. With multi-lane counting, the converter

receives accurate label counts for each roll. The machine can

thus count and inspect a variety of label shapes (not just

squares or rectangles), and the operator gets an accurate count

of labels per lane, regardless of varying label shapes or lengths.

Totalizer: Number of rolls made during a job

Accumulator: Total number of labels made during a job

Example of multi-lane print with different shapes and repeats

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2.3.4. Using Genesis to Catch Faults

―MMLD‖ is short for ―Matrix and Missing Label Detection‖. The matrix

for a set of die-cut labels is the empty (backing only) space between

labels on a roll. There are various sorts of matrix defects that can occur

on a roll.

First, there is the presence of existing matrix still located between

labels on the web. The Genesis can detect this material and indicate a

fault, allowing the operator to remove the excess material.

Second, defects in the printing process can lead to labels that are

missing or defective. The Genesis system detect the pattern of labels

on the web, using this pattern to determine whether a label is missing

or a partial label exists. Missing label detection will work with almost

any type of label, including labels with irregular edges or clear on clear

labels, with a minimum of 3mm x 3mm opaque print.

Label

Repeat

Electronic

Window

Leading Edge Trailing Edge Matrix

Web

Direction

Missing (or

Bad) Label*

* Trailing Edge detection (default setting).

Label edge detection can also be switched to

Leading Edge if likelihood of the label defects

is at the front of labels.

Detection of partial (bad) label may require

advanced inspection technology: ‗Pattern

Recognition‘, Vision System etc.

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Last, there can be defects in the splice or flag. The Genesis system

can help catch these faults as well.

With the most sophisticated missing label and matrix detection on the

market, the Genesis Advanced Control System can detect missing

labels in multiple lanes as well as detect the presence of a matrix.

Faults or interruptions are indicated by a red bar in the upper area of

the Genesis HMI signaling a problem. The operator need only touch

the bar to access the fault screen.

The defects managed can also be either detected by an vision system

or 3rd party inspection sensors (Barcode reader, etc.). Using a signal

from the device, Genesis can quickly place faults from any web speed

at a pre-determined position for editing. Precise fault placement

means no jogging the web, as the unit will move smoothly from full

speed to a stop at the correct location. Quick fault placement process

is optimized using fast signal processors to allow fast, precise

placement, all without compromising roll quality.

2.3.5. Four Genesis levels

There currently exist four Genesis ―levels‖ to suit customers‘ needs

and budgets. All four Genesis levels feature:

Integrated operator interface with large 15‖ full color touchscreen

o Critical functions consolidated to single screen

o Simplified interface provides shorter training time for operators

Smart defect management system

High speed processor - multiple functions process simultaneously

Precise fault placement

Advanced speed control and web handling

Configurable for either imperial or metric

Beyond these, these Genesis level needed will depend upon the

customer‘s particular needs and applications:

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Genesis Controller - Level 1

Linear Count: Indicates roll label count in multiples of 10‖, 12‖ or 10

CM lengths

Roll Totalizer – Counts total number of rolls per job

Label Count Accumulation – Counts total number of labels per job



CM lengths

Label Count via butt cut or gated counting:

o Butt Cut Count: Based on the label length captured through Auto

Setup or entered manually

o Gated Count: Detects leading or trailing edge of each label.

o Clear on clear labels must have opaque print of 3mm by 3mm or a

capacitive sensor (E03B) is required

Auto Setup allows for the automatic sensor calibrations and label

repeat length detection using a limited web sampling distance





CM lengths







Auto Setup feature allows for the automatic sensor calibrations and

label repeat length detection using a limited web sampling distance

Missing label and matrix detection with one channel included

Matrix and Missing/Bad Label – detects pattern of each label to

determine whether label is in place, or if matrix has been left in place.

Clear on clear labels require 3mm x 3mm opaque printed mark

minimum for detection

Splice or Flag – Detects splices or flags on web

Full Fault Placement - quickly places faults from any web speed at

pre-determined position for editing no jogging of the web

Roll Totalize – Counts total number of rolls per job


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CM lengths







Multi Lane Count: This mode allows counting of labels in multiple label

streams, even if streams do not have the same label length, within a

lane, labels must be the same repeat

Auto Setup feature allows for the automatic sensor calibrations and

label repeat length detection using a limited web sampling distance

Missing label and matrix detection with one channel included, detects

Matrix and Missing/Bad Label – detects pattern of each label to

determine whether label is in place, or if matrix has been left in place.

Clear on clear labels require 3mm x 3mm opaque printed mark

minimum for detection

Splice or Flag – Detects splices or flags on web

Full Fault Placement - quickly places faults from any web speed at

pre-determined position for editing with no jogging of the web



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2.4. eDrive Technology

eDrive (electronically synchronized motor drive system) is exclusive to

Rotoflex inspection/rewind equipment. This unique drive system

technology provides complete flexibility to process a wide range of

tension sensitive materials using precise web control. eDrive

technology utilizes advanced AC flux vector motor control, which does

not require any gear boxes, clutches or pneumatic brakes. This means

that eDrive proves better management of torque output and tension

control. The eDrive feature is now standard on all equipment in the

Rotoflex product line.

A common misconception is that servo drives are the most elite

technology for web control in inspection/rewinders. This is not always

the case. While servos have their place and serve as excellent motors

when precise shaft placement is critical (i.e. registering to a specific

mark), the AC flux vector motor found in the eDrive system is better at

managing the power supplied to the shaft, providing excellent tension

control. This advanced technology results in extremely accurate

tension at higher speeds and consistent performance and roll quality

across a wide range of materials.

Brush up:

A/C Flux Vector = dynamic torque control

Servo = motion or position control

Servos are best suited for operations demanding precise location

control, such as precise die cutting, printing, and spot-coating.

A/C Flux Vector best suited for operations where tension and speed

control are critical: Unwinding, rewinding, and slitting.

Rotoflex utilizes the best technology for the application

A/C Flux Vector rewinding, precise tension control

Servo Registration control, die cutting

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2.4.1. Value added

All units feature individual AC Vector Drives on rewind and draw

station, with individual motors used for each shaft on dual rewind

models. There are no clutches and brake pad systems to maintain,

which means less dust created during operation. These features,

coupled with excellent torque management and tension control,

means:

Consistent Performance

Systems with eDrive perform smoothly and consistently

Lower tension / higher speeds

Softer rolls with consistent rewind tension improves the quality of the

roll while reducing waste/rejection. All this is done at higher speeds,

meaning more productivity.

Electronically synchronized drive system

The eDrive systems integrated seamlessly with the Genesis quality

control system, electronically monitoring and synchronized the entire

system. This leads to better control and fewer errors.

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3.1. The LT-Vision System

The LT-Vision system is a cost effective 100% Print Inspection system

found exclusively on Rotoflex rewinders. It consists of a tube light

source, a camera, an encoder, and a data link to the Genesis system.

3.1.1. Value added

The LT-Vision system enhances quality control because it:

Is easy to use.

Gives the operator the defect

information they need when

they need it.

Works in conjunction with

Genesis to accurately place

defects.

Controls the inspection

standards being used.

Improves your customer‘s

competitive position.

Lower cost of ownership.

Configurations for 13-inch and

17-inch webs.

3. INSPECTION

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The LT Vision system closely integrates with the Genesis Advanced Control to provide accurate placement when a fault is detected

3.1.2. The Tube Light System

The Tube Light System (patent pending) is a lighting method that

used completely diffused lighting for print inspection. By using

diffused lighting, the system avoids artifacts and errors that can

occur when standard systems (such as Lightline) encounter glossy

or shiny materials. This makes Tube Light ideal for:

Foil decorated prints

Holograms

Embossed/debossed surfaces

Print on reflective (metalized)

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3.2. VSI: Compact Inspection/ Slitting/ Rewinding

The Rotoflex VSI is the most widely used machine in traditional roll-to-

roll label inspection, slitting and rewinding. It is known for its

outstanding reliability in demanding production environments. The VSI

features:

Easy access to all working areas, due to compact design

Limited waste and fast job changes with short web path

Advanced inspection capabilities with the Genesis Control

System

Precise tension and web handling capabilities provided by

eDrive system

Precision Slitting with an array of slitting options.

Compact design, making it easy to access and operate

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Specifications

VSI330 VSI440

Max. Web widths 13.25 inch /

337mm

17.25 inch / 440mm

Max unwind diameter 28 inch / 711mm 28 inch / 711mm

Max single spindle

rewind diameter

18 inch / 457mm * 18 inch / 457mm *

Max dual spindle

rewind diameter

16 inch / 406mm 16 inch / 406mm

Unwind/Rewind shaft

diameter

3 inch / 76 mm ** 3 inch / 76 mm **

Max speed 750 fpm / 230mpm 750 fpm / 230mpm

Draw station and

rewind drive

AC vector AC vector

Control system Powered by

Genesis

Powered by Genesis

* 15‖ rewind diameter with web gripper

** Fixed Pneumatic core type

Brush-up: fpm means “feet per minute”, a measure of how quickly a roll winds or unwinds. Similarly, mpm stands for “meters per minute”.

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Options

Roll lift

Slitters – crush knife, shear knife, razor and cartridge style

Automatic unwind tension control

Ultrasonic web guide sensor

40 inch / 1016mm unwind

Auto web gripper/feeder

Clear label count sensor

Matrix & missing label detection

Dual rewinds

Strobe lights

Horizontal unwind splicing table

Web clamp

Waste wind-up

LT 100% Web Inspection Vision System

Integration with complete range of inspection systems to meet

any application need!

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3.3. VLI: Advanced Inspection/ Slitting/ Rewinding

The Rotoflex VLI is a premier inspection, slitting and rewind system

with expanded capabilities for more advanced applications and high-

speed production. It is ideal for film, film packaging and other tension-

sensitive materials. The VLI can be configured to meet a full range of

applications and substrates. The VLI features:

Advanced rewinder to handle a wide range of materials and

applications:

• High throughput PSA

• Unsupported film

• Delicate materials

Ideal inspection, slitting and rewinding of unsupported film

High throughput from high web speed and rapid fault

placements

Support for widths up to 700mm, for high capacity printing

Rapid acceleration and deceleration without compromising roll

quality

Automatic tension/speed control on unwind, rewind and draw

station

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Specifications

VLI330 VLI440

Max. Web widths 13.25 inch / 337mm 17.25 inch / 440mm

Max unwind diameter

30 inch / 762mm 30 inch / 762mm

Max single spindle rewind diameter

24 inch / 610mm 24 inch / 610mm

Max dual spindle rewind diameter

24 inch / 610mm 24 inch / 610mm

Max speed 950 fpm / 260mpm 950 fpm / 260mpm

Draw station, unwind drive, and rewind drive

AC vector AC vector

Control system Powered by Genesis Powered by Genesis

VLI500 VLI600 VLI700

Max. Web widths 20.25 inch / 515mm

24.25 inch/ 610mm

28.25 inch/ 718mm

Max unwind diameter

30 inch / 762mm

30 inch / 762mm

30 inch / 762mm

Max single spindle rewind diameter

24 inch / 610mm

24 inch / 610mm

24 inch / 610mm

Max dual spindle rewind diameter

24 inch / 610mm

24 inch / 610mm

24 inch / 610mm

Max speed 950 fpm / 260mpm

950 fpm / 260mpm

950 fpm / 260mpm

Draw station, unwind drive, and rewind drive

AC vector AC vector AC vector

Control system Powered by Genesis

Powered by Genesis

Powered by Genesis

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Options

Roll lift

Slitters – crush knife, shear knife, razor and cartridge style

Ultrasonic web guide sensor

40 inch / 1016mm unwind stand

Differential coreholders

Ironing roller

Anti-static equipment


Clear label count sensor

Matrix & missing label detection

Dual rewinds

Strobe lights

Web clamp

Semi-automatic turret

Waste wind-up

LT 100% Web Inspection Vision System

Integration with complete range of inspection systems to meet

any application need!

40" Rewind Stand Cartridge Slitter

31


3.4. DSI: Inspection/Slitting with Die Cutting

The DSI is a dual-use machine with die cutting and inspection/slitting

capabilities. A stand-alone die cutting system like the DSI is an ideal

solution for label converters wanting to meet the demand for blank

label products, since it allows the converter to die-cut labels without

having to put the roll on a press first. The DSI also has inspection and

slitting capabilities comparable to the VSI (see section 2.3.1). The DSI

has the following standard features:

Available in 330 mm and 440 mm

Genesis advanced control system

Auto stop and roll end shut off

Controlled acceleration/deceleration

AC vector drive on rewind

Full auto-tension control on rewind

Adjustable hardened splicing table on unwind

Front inspection position

Electronic single edge web guiding system

Pre-determining electronic counting

Pre-select slowdown

Side mount jog pedal

Totalizer

Dual die-station

units feature

manual adjust

registration

control

32


Specifications

DSI 330 DSI 440

Max web width 13.25 inch / 337 mm 17.25 inch / 438

mm

Max unwind diameter 28 inch / 711 mm 28 inch / 711 mm

Max rewind diameter 18 inch / 457 mm 18 inch / 457 mm

Max speed 750 fpm / 230 m/min* 750 fpm / 230

m/min*

Die station and rewind drive

AC vector AC vector

Control system Powered by Genesis Powered by

Genesis

* Inspection & slitting speed

33


Options

Shear knife, crush knife, or razor slitter

Roll lift

Unwind stand

Semi-automatic 2-spindle turret

Printed line guide

Static eliminator


Flag/millsplice detector

Matrix and missing label detector

Sheeter station with conveyor/stacker

Overscorer or Underscorer

Ironing roller

Bow roller

Clear on clear count sensor

High intensity strobe light

Dual rewind

34


3.5. Options

Each Rotoflex machine has a number of options available. This makes

it possible to configure Rotoflex machines to meet the specific

demands of each customer. A full list of options, and the machines

they are available on, can be found in section 5.1.

Here we will review some of the more common options for inspection,

slitting, and rewinding.

3.5.1. Common Options for Roll Inspection/Counting

Flag and Millsplice Detection: Senses press flags or mill-

splices and places fault on splice table

Full Fault Placement: Provides additional web accumulation to

aid accurate fault placement at full speed (this option is

included in Genesis Level 3 & 4; see section 2.5.3)

Waste Wind-up: Coreless windup shaft placed near splice table

to wind up extended lengths of waste

Capacitive Count Sensor: Required for clear-on-clear labels

with little to no marking. Senses variations in material thickness

to detect label presence

3.5.2. Common Options for Slitting

Typically, there are three types of slitters: shear slitters, crush slitters,

and razor slitters. The following chart outlines the advantages and

disadvantages of each:

Sheer Slitting Crush Slitting Razor Slitting

35


Sheer Slitting Crush Slitting Razor Slitting

Recommended for slitting:

Paper

Paper/Paper labels

Clear/Clear labels

Clear/Paper labels

Foil

Board


Paper

Paper/Paper labels

Clear/Clear labels

Clear/Paper labels

Foil

Board


Paper/Paper labels

Clear/Clear labels

Clear/Paper labels

Foil

Unsupported film

Advantages:

Clean cutting of material

Low dust

Easy lateral adjust

Advantages:

Easy knife access and adjustment

Best solution for adhesive backed web

Advantages:

Clean cutting

Low dust

Well suited to thin substrates

Disadvantages:

Requires more time for set up

Not usually suitable for unsupported films or very thin substrates

Disadvantages:

Edge of material not clean after cut

High dust

Disadvantages:

Blades dull quickly in some materials

Requires web to be under tension – driven idler

The Sheer slitting system consists of a demountable, two shaft

cartridge and easily positioned spring loaded upper and lower cutting

blades. The system runs slightly faster than the web. This creates a

scissor-like cutting action which minimizes slitting dust and maximizes

blade life. Sheer cutting is ideal for slitting silicone backed papers as

well as heavier papers and cardstock.

A Crush slitting system uses a conventional air-loaded crush knife

assembly. A crush knife can be installed to provide quick set-up for

short run jobs, or for occasional stock splitting.

36


A Razor slitting system uses a series of fixed razors to slit the web as it

moves through the slitter. Razor systems are well suited to thin

materials and produce a clean precise cut with little dust or waste.

However, it does require the web to be under tension, so that the

razors cut appropriately. Units equipped with razor slitter will feature a

driven roller after the slitter to provide tension through the web.

3.5.3. Common Options for Rewinding and Unwinding

Proper control of the web during unwinding, inspection, slitting, and

rewinding is absolutely critical to avoiding wrinkles and other defects.

Rotoflex machines come with a number of options to help control rolls

as they pass through, and out of, the machine:

Web Gripper: Speeds cycle

time by gripping and

delivering cut streams to

cores for taping – operator

does not need to fumble

around trying to grab loose

streams

Separate Unwind Stand

with Roll Lift: Handles rolls

up to 40‖ in diameter,

includes pnuematic, two-arm

lift.

37


Dual Rewind: Splits slit

streams onto upper and

lower shafts, useful when

cutting very narrow streams

or when material has a

tendency to interweave,

making finished rolls difficult

to separate.

Ironing or Lay-on rollers:

Eliminates air between layers

when winding unsupported

film, resulting in straighter,

more uniform rolls.

On-board Roll Lift: Lifts and

positions full rolls for

machines equipped with

onboard unwinds

There are, of course, many more options available to the converter. When preparing a quote, you will need to get as much detailed information as you can about a potential customer‘s processes and needs.

38


4.1. The Sales Process

Like many other process, selling capital equipment requires a number

of steps. Over the past few years, Mark Andy, Inc. has refined its

selling process for all its premier brands. This process consists of four

phases.

Mastering each of these steps could be the subject of a book in itself.

The following, then, is just a rough-and-ready guide (or, for some, a

refresher) in how to sell successfully.

4.1.1. Phase I – Identify and Qualify an Opportunity

Sometimes, a new sales opportunity will come to you. Either a

potential customer will call you, or someone you know will give you a

lead. However, other times it is often necessary to do some research

to identify potential clients.

To begin with, you might want to consider targeting companies that are

in industries likely to use finishing and inspection equipment.

Examples of such industries include:

Food & Beverage

The food & beverage industry is one of constant competition. The

ability to include key information while keeping a package attractive is

4. SELLING ROTOFLEX

39


critical. Solutions from Rotoflex are implemented daily to ensure

accurate, consistent rewinding and finishing of labels and packaging

for the food & beverage industry.

Wine & Spirits

The variety of labels you will find on wines & spirits may be as large as

the variety of wines themselves. Examples of Rotoflex finishing and

converting solutions can be found on wine & spirit bottles across the

globe.

Health and Beauty

Consumers rely on product packaging both for information and

aesthetics. This is especially important in the health & beauty market.

For consistent skin tones and vibrant colors, look no further than

machine solutions from Rotoflex.

Pharmaceutical/Nutraceutical

Globally, governments are getting more involved in the packaging and

labeling of pharmaceutical and nutraceutical products. There is

increased pressure to include significant amounts of information and

specifications on the packaging, as well as a requirement to make

these products traceable throughout their life cycle. Technology and

innovations from Rotoflex are able to accommodate these

requirements and more.

General Consumer

Packaging, package decoration and labels are found on almost every

product you encounter on a daily basis - consumer electronics,

multimedia products, private-labeled items and even furniture. Each of

these presents a printed decoration opportunity. Converting equipment

from Rotoflex can help you to label and package these items with high-

quality and durable products.

http://www.markandy.com/rotoflex/markets/wine-spirits.html

40


Automotive

In the automobile manufacturing industry specialty labels and other

high-tech adhesive applications provide brand information while others

provide instruction as to the intended use, function or protection of the

product. These labels need to be able to withstand a variety of

elements and conditions. Rotoflex has specialized in equipment to

convert these labels for years.

Industrial

Industrial labels and packaging come in a variety of sizes and shapes.

Whatever the design, the requirement that the label be resistant to

elements such as water and chemicals is paramount.

Once customer information is collected, it is then identified and

qualified. This is where a prospect is reviewed and qualified as a viable

buyer of equipment – having enough capital to make a purchase, the

desire to use our type of converting equipment, and that closely

matches the converting equipment in a configuration that Rotoflex can

build.

4.1.2. Phase II – Finding and Presenting a Solution

Your job as a consultant is to try to understand the processes that the

potential customer carries out, and to think of ways that the potential

customer can improve these processes. For example, is there a way

that a Rotoflex machine can help cut down on waste? Or speed up

important jobs? Or allow for more flexibility in who operates the

machines? Every Rotoflex machine is a host of solutions to potential

customer problems. You will need to discover what these problems

are.

As a qualified customer reveals and discloses their converting needs

and applications, a plan is put into motion to further the process and

develop a solution to best fit the customer‘s need. This phase also

investigates and analyzes the capital or monies available to make the

purchase. All this information is collected and then integrated into

developing the ideal machine solution to achieve their need.

41


Once you have a clear picture of a potential customer‘s needs, you will

know whether a Rotoflex solution is right for them—and, if so, which

one. Section 2, ―Products and Features‖, outlines the machines in the

Rotoflex line. Section 2 also has a quick summary chart of the three

main Rotoflex machines—a handy reference for matching machine to

customer need.

Remember, selling is about solving a customer‘s problems, not about

making them buy a piece of equipment. You should think about

Rotoflex machines not in terms of their features and specifications, but

rather in terms of how they can solve a customer‘s specific problems.

Once a machine plan and budgetary sale price is formulated, a plan is

put together in order to build confidence with the customer to make the

purchase. One or more demonstrations or machine tests/validations

may be needed to continue pushing the process along. The demo and

company visit are also important steps in driving toward a closed sale.

It provides and opportunity for a customer to experience how he will be

managed by more than just the sales person. A well organized visit

will be performed at the location designated.

4.1.3. Phase III – Quote and Formal Proposal

There are two critical forms you will need to complete at this point.

The first is the Sales Worksheet. The Sales Worksheet:

• Establishes machine configuration for quoting;

• Provides a initial list price estimate;

• Breakout options note the price of individual options in the quote

without including in the quoted price;

42


The Sales Worksheet helps ensure that the customer is getting the

right solution, and at the right price.

Sales Prepared By:

Worksheet Customer: Example Co. Date: 4/25/11

Contact: Mr. Example

Address: 123 Example Way

Tel: 555.555.5555

Fax:

Email: [email protected]

Site Information Voltage Frequency

Language Spanish If other than English

Conversion Factor

Model: VLI-330EBreakout Extended

Options Qty Part Number Description Price List Price

1 Base BASE PRICE 35,340 35,340

1 M01L Cartridge shear slitting system (manual adjust) 6,370 6,370

1 M06 Auto web gripper / feeder - limits rewind diameter to 15" 2,730 2,730

1 M16 Roll lift (for machines without separate unwind stand (M15) 8,113 8,113

1 E01D Ultrasonic web guide sensor 1,201 1,201

1 E05 Electronic flag/millsplice detection 2,180 2,180

1 E10D High intensity strobe 4,154 4,154

1 E16 Full fault placement 2,640 2,640

1 EGEN2 Genesis - Level 2 (linear, label and butt cut count) 3,520 3,520

1 M01A Additional shear knife 274 274

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

Total Engineering Content 0 0

1 Base Machine Total Price 66,521

= 1 USD:

Currency Name:

480V

380V

208-240V

60 Hz

50 Hz

43


The second critical form is the Application Form. The Application form

is very important, because it communicates customer requirements

and application. Thus the Application Form:

• Ensures that better quality machines shipped to customer;

• Ensures the best machine configuration for the application;

• Helps avoids issues with unique materials or requirements;

• Indentifies key questions that need to be answered during

configuration;

Application Worksheet/Special Design Request Form

Customer: Example Co. Sales Rep: 0

Address 123 Example Way Technical Contact: Example Engineer

Phone:

Phone: 555.555.5555 Admin Contact:

Email: [email protected] Phone:

SDREF # Model: VLI-330E

Special Design Request?

1. What is the application?

2. What is the customer's intended use for the equipment

Pressure Sensitive Labels Substrate Thickness

Paper/Paper .004" - .008" (need mm)

PS Labels will be a ___ use of the rewinder Paper/Film Other

Primary Film/Paper

Secondary Film/Film

Is the Film/Film clear? Sample Available?

Will any materials have a perforated web?

Unsupported Film Products Substrate Thickness

BOPP inches mm

Film will be a ___ use of the rewinder PVC inches mm

Primary PET Polyester inches mm

Secondary Polystyrene inches mm

Other

Are materials clear? Sample Available?

Other Substrate Specifications

Foil

Material will be a ___ use of the rewinder Paper

Primary Paperboard

Secondary Other (Describe)

Do any materials consist of 3 or more layers Sample Available?

What is the minimum web width the customer will run on this machine? 6"

Yes No Yes No

Yes No

Yes No

Yes No

Yes No

Visual inspection, slitting and rewinding of pressure sensative labels

Yes No

Yes No

44


Most of the information required in the Application Form should have

been unearthed during the qualification and solution finding steps.

In addition to these forms, you will need to propose the solution to the

customer. Sometimes this will take the form of presentation;

sometimes, it will simply be a quote. Presentations should highlight

the benefits of using a Rotoflex machine for the customer, and should

also allow the customer time to ask any questions. Quotes are much

more straightforward. Rotoflex formal quotes generated at any global

Mark Andy, Inc. sales office provide consistent and detailed format.

It is important to remember how the quoting process works. Once you

have identified a potential customer‘s needs, you must submit both a

Sales Worksheet and an Application Form to the internal sales contact

(i.e. territory manager, direct sales contact or contract admin). A

3. Are there any other materials that will be run on this machine? If so please explain:

4. What are the slitting and roll quality requirements? 5. What are the customer inspection requirements?

What is the minimum slit width the customer will require? Visual - Inspection Plate

2" Missing Label and Matrix Detection

What is the max. number of streams the customer will slit? 100% Inspection - Vision System

6 Does the customer require fault placement?

Finished Roll Tension

Low Location: Splice Table Inspection Plate

Med Other

High

6. Does the customer expect to utilize any third party equipment with the machine?

Vision System Integration

Make Integration provided by Rotoflex at factory

Model Integration provided by third party at customer site

Ink Jet Integration

Make Integration provided by Rotoflex at factory

Model Integration provided by third party at customer site

Front Side Printing

Backside printing Other Printing

Sequential Numbering

Other

7. Are there any special processes or equipment requirements for this machine?

Provide a short description of any additional or unique materials the customers expects to run on the machine along with

specifications for the material.

Provide a short description of any special process the customers expects to run on the machine.

Yes No

Unless noted, machine will

be configured to wind low

tension finished rolls

45


preliminary quote will then be generated but please note - a quote will

not be provided without a completed application worksheet!

If a special design is required for the application, the forms are sent to

your internal sales contact who helps complete a SDR form. The

quoting representative from Mark Andy, Inc. then incorporates the

SDRs and/or configuration changes into the quote. He or she then

sends the preliminary quote to customer and/or salesperson.

4.1.4. Phase IV – Close and Build Implementation

Congratulations, you have won the order! With an order and down

payment, the STO process begins inside the manufacturing group.

This begins the process of building the machine for your customer.

Even when a customer has approved and purchased a solution, your

job is not yet done. In your role of consultant, you will want to verify

that the machine is STO‘d, built to specification, delivered and installed

properly and on time. You will want to ensure the customer is provided

adequate training, and that the operators are comfortable with the

machine‘s use. Much customer support is handled by the MAX service

department. However, building a relationship with a new client is

important for you too. Strong customer relations help to guarantee re-

orders, garner recommendations, and sometimes even generate leads.

4.2. Competitive Response

There are number of competitors to Rotoflex. Each has its own unique

way of devaluing Rotoflex and trying to grab market share. You should

be ready to respond to competitors, especially if one of these

competitors is also talking to one of your potential customers.

46


4.2.1. AB Graphics

AB Graphics is an international company specializing in modular digital

converting, inspection rewinding equipment and turret rewinding.

Competitive

Attack

Our Response Customer Value

―We (ABG) now

have a vertical

inspection style

machine‖

Vertical inspection is

Rotoflex core design.

We have more

experience and tension

management technology

than anyone else.

Better motion control

means shorter accel

and decel times, and

better quality rolls =

more productivity

―RF is old

technology‖

We have the new

Genesis controller that

brings many productivity

benefits to the converter.

We also have also the LT

vision system.

Higher productivity

Easier to use

More capabilities

―Because we

(ABG), are lower

cost‖

Rotoflex has always

been the premium brand

– for good reason:

Better technology, better

service, etc.

Productivity and quality

value outweigh shipping

costs….

Our Attack Points

• ABG is focused on digital finishing and turret rewinders; slitter

rewinders are a minor part

• ABG is not a premium brand. The technology in motion control

and web management is not as sophisticated as Rotoflex.

47


4.2.2. Prati

Prati is an international company, based in Italy, that specializes in

inspection machines, die-cutters, and similar products.

Competitive Attack Our Response Customer Value

―We (Prati) are a family

run company and are

easy to do business

with.

Rotoflex, as part of Mark

Andy has a global

presence and strong

backing and is able to

support customers

world-wide.

A strong financial

backing makes us

stable

―We (Prati) have better

technology‖.

We have:

The New Genesis

controller.

The New LT vision

system.

The New low profile DLI

machines.

Capability

Quality

Productivity

Productivity

Our Attack points

Prati has only the horizontal style of finisher.

Prati is a smaller company, and cannot offer the sales and

support at the same level of Rotoflex.

48


4.2.3. Rotocontrol

Rotocontrol is a start-up German company that produces high speed

machines for high-speed inspection, cutting and rewinding machines

for the label industry. Their machine use mainly Servo technology.

Competitive

Attack

Our Response Customer Value

―RF is old

technology. They

haven‘t changed

technology in

years‖ (Rotocontrol

saying this)

We have developed:

Genesis

LT Vision

E-drive

Capability,

productivity

Quality assurance,

productivity

Productivity, roll

quality

Productivity, quality

assurance

Ease of training

―We (Rotocontrol)

are the new

Rotoflex‖

The original Rotoflex is back,

stronger than ever, with

strong financial backing and a

desire to grow.

Stability

―We (Rotocontrol)

have more

products than RF

has – turrets,

diecutters‖

Rotoflex can offer any

ancillary equipment that is

needed, through our strategic

partnerships.

Stability, partnerships

―We‘ll (Rotocontrol)

reduce price to

what-ever is

needed to get the

business.‖

This is a short term strategy

and can lead to future

financial issues.

Stability

49


Our Attack points

• Rotocontrol is a small startup company with limited resources.

They don‘t design their own products, and they don‘t even

manufacture themselves!

• By discounting so much, they are just funding current projects

with future down payments – which is financially unstable.

• Rotoflex has a much larger service and support structure

globally.

• Limited to how many units they can produce – which means

long lead times.

4.2.4. Local Builders

Sometimes, competition does not come from large international

companies. Rather, the competition comes from small, locally owned

companies. Though smaller, these companies often offer support at

the local level—which customers often assume means better support.

This is not always the case, however.

Claim Response

―We have servo

technology!‖

Technology is no value without the web-

handling experience to back it up.

Servos are not the ideal technology for

dynamic tension control.

―We are local and can

provide good support.‖

Can they provide long term support?

Rotoflex large install base and backing for

MA means available product support out

into the future.

―We have inspection

capabilities!‖

Can they provide the advanced fault

detection and counting capability for

Rotoflex?

Genesis is the most advance fault

detection/ placement and counter on the

market

50


Our Attack points

• Genesis and eDrive provide the most advanced

inspection/counting and web handling capabilities available.

• MA support and backing means Rotoflex units can be easily

serviced for years to come.

51


Enhancements & Upgrades [email protected]

Parts [email protected]

Performance Maximization [email protected]

Rebuilds [email protected]

Technical Service [email protected]

Training [email protected]

5. SERVICE INFORMATION

mailto:[email protected]






52


6.1. Rotoflex Options Summary

There is a wide array of options available for Rotoflex machines. The

following is a complete list of those options along with descriptions

detailing their functionality. The options are grouped by functional

area, starting with unwind and web guiding options, slitting options,

rewind options and finally, inspection options.

6. APPENDICES

Code

Description Model

Unwind and Web Guiding Options

M15F Separate unwind stand with AC vector motor Handles larger 40‖ (1 meter) diameter rolls. Includes built-in pneumatically operated lift and web guide with splice table. Tension control provided by an AC flux vector motor drive

VLI

M15G

Separate unwind stand with magnetic particle brake Handles larger 40‖ (1 meter) diameter rolls. Includes built-in pneumatically operated lift and web guide with splice table. Tension control provided by a magnetic particle brake

VSI, DSI

M16 Roll lift for on board unwind Slide-out lift allows rolls to be rolled into position, lifted to the desired height and easily slid onto the unwind shaft. For machines utilizing onboard unwind only. Not required on machines equipped with M15F or M15G

VSI, VLI, DSI, DLI, Vericut

M32A Horizontal unwind splicing table Additional splice table positioned just after the unwind. Allows easy change-out of unwind rolls without need to re-web.

VSI, DSI

E01A Center web guiding Adds a second optical edge guide sensor to the opposite side of the web. Helps to maintain the centre of the web in a fixed position even if the material varies in width. This option is especially helpful when doing dieslitting or diecutting of unprinted products

VSI, VLI, DSI, DLI

E01B Printed line guide Provides a line guide sensor which is reflective in nature and causes the system to guide relative to the edge of a printed line.

VSI, VLI, DSI, DLI

E01D Ultrasonic web guide sensor Provides accurate web guiding with transparent web, recommended for unsupported film and clear on clear label applications

VSI, VLI, DSI, DLI

53


Slitting Options

M01 Shear Slitter The shear knife cutting system consists of a demountable, two shaft cartridge and easily positioned, spring loaded upper and lower cutting blades. The system is geared to run slightly faster than the web to create a scissor-like cutting action which minimizes slitting dust and maximizes cutting blade life. Shear cutting is ideal for slitting silicone backing papers as well as heavier papers and paperboard card stock.


M01A Additional shear knife Shear knife set, compatible with options M01, M01H, M01L or M01J


M01G

Provision for future shear - M01 Provides mounting locations and hardware for installation of shear slitter in future


M01H

Cartridge shear slitting system (motorized) Similar in cutting action to a standard shear slitter, the cartridge shear cutting system features a removable insert to allow for off-line setup or interchangeability with other preset cartridges to reduce downtime between jobs. In addition, allows easy change-over to razor slitting system vie the razor cartridge option (M03F) Each shear cartridge has a convenient manual disconnect mechanism which separates the upper and lower blades so that uncut material can be fed through the system to reduce waste during threading or to allow the slitting system to be bypassed. This option features motorized lateral adjustment to aid in slitter setup.


M01J Extra shear cartridge for option M01H or M01L Quick change cartridge inserts, compatible options M01H, M01L, M03D and M03E. Extra cartridges can help speed set up times between jobs by allowing the slitter spacing to be pre-set before job changeover.


M01K Setup stand with digital setup for cartridge shear slitter Allows fast setup of shear cartridges using a separate setup stand. Features a digital caliper to provide extremely accurate knife spacing.


M01L Cartridge shear slitting system (manual adjust) Similar in cutting action to a standard shear slitter, the cartridge shear cutting system features a removable insert to allow for off-line setup or interchangeability with other preset cartridges to reduce downtime between jobs. In addition, allows easy change-over to razor slitting system vie the razor cartridge option (M03F) Each shear cartridge has a convenient manual disconnect mechanism which separates the upper and lower blades so that uncut material can be fed through the system to reduce waste during threading or to allow the slitting system to be bypassed. This option features a manual lateral adjustment to aid in slitter setup.


M02 Crush knife slitter A convenient crush cutting assembly, which uses conventional air loaded crush knife assemblies, can be installed to provide quick setup for short run jobs or for occasional stock slitting requirements.


54


M02A Additional crush knife Additional crush knife assembly, compatible with M02


M02B Preparation for crush knife Provides mounting locations and hardware for installation of crush knife slitter in future


M03A Additional razor blade holder (for M03)

M03C

Preparation for standard razor slitting unit (M03) Provides mounting locations and hardware for installation of razor slitter in future

M03D

Cartridge Razor Knife Slitting System (Motorized) Similar in cutting action to a standard razor slitter, the cartridge razor slitting system features a removable insert to allow for off-line setup or interchangeability with other preset cartridges to reduce downtime between jobs. In addition, allows easy change-over to shear slitting vie the shear slitting cartridge option (M01J). Cartridge razor slitter feature adjustable razor holders that cut from the top, providing easy on-machine setup. This option features motorized lateral adjustment to aid in slitter setup.


M03E Cartridge Razor Knife Slitting System (Manual) Similar in cutting action to a standard razor slitter, the cartridge razor slitting system features a removable insert to allow for off-line setup or interchangeability with other preset cartridges to reduce downtime between jobs. In addition, allows easy change-over to shear slitting vie the shear slitting cartridge option (M01J). Cartridge razor slitter feature easy-to-adjust razor holders that cut from the top, providing easy on-machine setup. This option features a manual lateral adjustment to aid in slitter setup.


M03F Razor Knife Cartridge for Option M03D or M03E Quick change cartridge inserts, compatible options M01H, M01L, M03D and M03E. Extra cartridges can help speed set up times between jobs by allowing the slitter spacing to be pre-set before job changeover.


M03G

Additional razor blade holder for cartridge slitter Top cutting type razor blade holder specifically for the cartridge razor slitter, compatible with options M03D, M03E and M03F


M11 Trim removal A vacuum system used to draw the material away from the rewind of the machine and blow it to a remote location for later disposal. Required when slitting off edge material from the web.


55


Rewind Options

M06 Auto web gripper / feeder The automatic web gripper/feeder is a unique feature which greatly increases the efficiency and productivity of the finishing operation by making it easy for the operator to finish one rewind cycle and set up the next cycle without losing web tension. The pneumatically operated gripper feeder is automatically engaged at the completion of each count sequence to hold the web secure when the machine has come to rest. This enables the operator to conveniently cut, close and remove the rewind rolls and then prepare the rewind shaft with new cores before jogging the loose web ends forward to permit taping - all under complete web tension control. Once the new cycle is started, the gripper/feeder mechanism automatically disengages again until the end of the next cycle.


M06A Web clamp Holds web in place on last idler before rewind shaft to maintain web tension during core changes and to make starting new rolls easier for operator


M06B Provision for future web gripper Provides mounting points to allow a web gripper to be installed at a later date


M08A Dual rewind Provides second rewind shaft positioned below the first. Used when there is need to rewind unsupported or narrow width materials which have a tendency to interweave on a single rewind shaft. The operator simply alternates the slit webs to each of the rewind shafts and proceeds as normal.


M08B Preparation for dual rewind Provides mounting location to allow a second rewind shaft and drive to be installed at a later date


M09A Semi-automatic turret (2 spindle)


M13 Ironing roller Sometimes called a lay-on roller, places pressure on rolls when winding to remove air between layers, ensuring a consistent, tight roll. Most often used when winding unsupported films


M14 Bow roller An idler with slight bow to surface placed just before the rewind shaft, used as an alternative to dual rewind shafts. Running the slit webs over the centre of the bowed roller effectively separates the webs to allow single shaft rewinding of unsupported or narrow width materials.


E09 Static eliminator VSI, VLI, DSI, DLI, Vericut

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Inspection and Counting

EGEN1

Genesis - Level 1 Included with all Rotoflex rewinders, Genesis is an intuitive, flexible control system, that by utilizing a simple HMI, operators can monitor all functions and view clear identification of faults and issues from a single screen. Integration of the system into multiple machines on the production floor allows operators to easily transfer from one machine to another without relearning the intricacies of a new control system. In addition to operator benefits, the converter receives the benefits of increased productivity and revenue. With faster acceleration and deceleration, overall cycle times are shortened, and with recallable job recipes, repeat jobs can be run with virtually no setup time. The system is compatible and easily integrated with a variety of vision and detection systems Level 1 Features:

15 inch color touchscreen operator interface

Lineal count - 10 inch, 12 inch, 10 DM


Totalizer

Roll count

VSI, VLI, DSI, DLI

EGEN2

Genesis - Level 2 Level 2 Features



Label count and butt cut count


Totalizer

Roll count

VSI, VLI, DSI, DLI

EGEN3





Missing label and matrix detection (MMLD) with one channel included

Maximum 15 MMLD channels available


Automatic setup feature

Totalizer

Roll count

Full fault placement

VSI, VLI, DSI, DLI

57


EGEN4





Missing label and matrix detection (MMLD) with one channel included

Maximum 8 MMLD channels available


Automatic setup feature

Totalizer

Roll count

Multi-lane label count including one channel

Maximum 8 multi-lane counting channels available

Full fault placement

VSI, VLI, DSI, DLI

E19G E+L Vision System LT Provides full 100% inspection of labels and printed materials using a Rotoflex exclusive, high quality 4K color camera inspection system. When integrated with the Genesis control system, provides accurate detection and placement of a wide range of faults including missing or filled text, blurs and streaks, register inaccuracies and color variation. Mounted directly on the rewinder, requires Genesis Level 2 or higher. May require E01F depending on quality of roll from press.

VSI, VLI

E01F Webguide for LT vision system Adds web guide mounted just before the vision system to ensure the web is in a consistent position upon entering the camera. Required when rolls wound by the press may not be straight.

VSI, VLI

E03B Clear on clear count Utilizes a capacitive sensor to count individual clear labels, even without printing, using non-optical thickness technology. Requires Genesis Level 2 or higher.

VSI, VLI, DSI, DLI

E03C Eyemark count Provides accurate count of an eyemark or other printed indicator present on the web. Requires Genesis Level 2 or higher.

VSI, VLI, DSI, DLI

E05 Electronic flag/millsplice detection A reflective sensing system which will detect splices as well as flags, bringing the machine to a controlled stop whenever a flag or millsplice is sensed so critical inspection and correction measures can be taken

VSI, VLI, DSI

E06E Additional channel for MMLD and Multi-lane label counting Sensor assembly for addition lanes of missing label or row count (required EGEN3 or EGEN4 Option

VSI, VLI, DSI, DLI

E10 Strobe: standard intensity (20w) Standard output strobe; illuminates the inspection plate allowing the operator to easily see faults and inconsistencies in printed web. Automatically changes strobe rate to match run speed.

VSI, VLI, DSI, DLI

E10D High intensity strobe Brighter, higher output strobe; illuminates the inspection plate allowing the operator to easily see faults and inconsistencies in printed web. Automatically changes strobe rate to match run speed.

VSI, VLI, DSI, DLI

58


E13A Ultrasonic tension control on unwind Utilizes an ultrasonic feedback sensor to modify braking pressure as the roll size changes.

VSI, DSI

E16 Full fault placement Provides precise fault placement at splice table when operating the rewinder at high speed, used in conjunction with vision systems and other fault detection devices.

VSI, VLI, DSI

M10 Waste wind up Provides a coreless rewind shaft, located just above the fault editing splicing table operated by foot pedal. Assists in the removal of larger amounts of waste or defective material.


E20A Independent Inspection Stand Provides location to integrate third party Vision systems. Includes mounting location, web guide with ultrasonic sensor and web accumulation idlers.

VSI, VLI

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Die Cutting

M22E Die adapters and blocks DSI, DLI

M22G Lateral adjust die blocks DSI, DLI

M22J Second die station (for Model DSI) Equips DSI with second die station, useful in blank label operations such as perforations in the web. Die station features a 15‖ repeat fixed anvil with an outfeed nip roller

DSI

M22K Provision for second die stn (for Model DSI) Expands DSI frame and provides mounting points for second die station

DSI

M22S Sheeter station with conveyor/stacker DSI

M22T Conveyor for sheeting DSI, DLI Vericut

M27B Under scorer A system of finely adjustable score knives and a hardened anvil roller. Can overscore of the face material or underscore of the liner without use of a die-cutting or die-slitting station.

VSI, VLI, DSI, DLI

M27C Additional blades for under scorer (M27B)

E25C Servo Driven Registration System (Single Die Station) Allows in-register die cutting on a DLI when equipped with a single die station.

DLI

E25D Servo Driven Registration System (Dual Die Station) Allows in-register die cutting on a DLI when equipped with 2 or more die stations.

DLI

Additional Options

M30 Model 2 cabinet Extends mechanical cabinet to position user interface to the left side of the operator as he or she views the inspection plate.

VLI

M31B Fanfolder Interface DSI, DLI

M33 Side mount jog pedal Foot pedal that jogs the web at a pre-set speed, located near the splice table. Allows easy repairs without need to reach for a jog button. Included with VLI and DSI models.

VSI

M45 Rustproofing Coats exposed steel surfaces with the rust inhibitor just prior to packing. Recommended for units shipped via ocean freight.


E09 Static eliminator VSI, VLI, DSI, DLI, Vericut

E17 Core label printer

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6.2. Application Worksheet

6.3. Validation Questionnaire

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