REDUCE WEB BREAKS AND BROKE

• Web breaks and broke waste all previously invested resources - from materials to personnel costs.
• In addition, web breaks lead to a quality-restricted start-up phase.
• Irregular machine operation has a negative impact on the entire production line.
• Reducing unplanned downtime leads to more production.

With our know-how, products and solutions, we can help you to reduce web breaks and broke as follows - and all while maintaining or even improving product quality:

• Reduction of unplanned paper breaks and interruptions to save resources to
  • achieve a high level of production and
  • continuously produce homogeneous product quality.
• Understand the causes of paper breaks in order to avoid them in the future.
• Targeted optimization of machine sections to
  • avoid unplanned interruptions and downtime,
  • and boost overall machine efficiency.

All projects presented…

• ... show that it is possible to save resources while reducing production cost.
• ... achieved consistent or even improved product quality.
• ... have a return on investment of a few months only taking into account the overall added value achieved.
• ... have been implemented many times - no prototypes or trial installations.

TARGETS ACHIEVED

• Reduction of web breaks by 40% through improved root cause analysis.
• Increased production due to fewer paper breaks of 8,200 t/a.
• Same or even improved product quality.
• Return on investment within a few months.

TARGETS ACHIEVED

• More stable run on the winder.
• No production slow down of entire line.
• Reduction of web breaks as there is no contact marker to web.
• Significantly reduced quality costs due to improved defect detection.
• Savings on ink, no consumable at all.
• Savings on maintenance & spare parts.
• Same or even improved product quality.
• Return on investment within a few months.

TARGETS ACHIEVED

• Fully automatic sheet transfer to new reel spool.
• Loose winding of the paper web on the parent roll is avoided.
• Creasing on the reel core reduced to a minimum.
• Annual production significantly increased.
• Lowest investment costs compared to alternatives.
• Increased safety for operating personnel.
• Return on investment of just a few months.

TARGETS ACHIEVED

• Fully automatic sheet transfer to new reel spool.
• Loose winding of the paper web on the parent roll is avoided.
• Creasing on the reel core reduced to a minimum.
• Annual production increased by 530 tons.
• Increased safety for operating personnel.
• Return on investment of just a few months.

TARGETS ACHIEVED

• Markings on core of new reel spool significantly reduced.
• Annual production increased by 315 tons.
• Reduced wear on the existing reel change system.
• Reduction of faults.
• Increased reel change reliability = fewer web breaks, more production.

TARGETS ACHIEVED

• Reduction of paper breaks related to edge trim by 85%.
• This enables additional production of 430 t/a.
• Same or even improved product quality.
• Return on investment within a few months.

TARGETS ACHIEVED

• Increased service life of metering rods by 80%.
• Approx. 8 metering units less needed per year.
• Decreased number of required metering rod changes => leads to reduced production loss.

TARGETS ACHIEVED

• Metering rod change-over time shortened by 50%.
• Metering rods changed by customer at every paper break.
• Less required metering rod change-over time => leads to reduced production loss.

TARGETS ACHIEVED

• 2 machine stops due to guiding system failure per year eliminated.
• No more damages to dryer fabric.
• Costs for spare parts significantly reduced.