What can I do to minimize roll change time?
Posted on | by caitlin

Well run sheeter operations require about 1 – 2 minutes to change a roll for shaftless roll stands and 5 – 8 minutes to change a shafted roll when using air shafts.  To minimize roll change time:

  • While the current roll is being sheeted, prepare the next roll to be loaded
    • Strip the wrapper and headers from the roll
    • Inspect the roll for edge damage, addressing as required
    • For shaftless roll stands, positon the rolls off line, ready for loading
    • For shafted roll stands , using a second set of shafts, pre shaft the rolls
  • Stop the sheeter before the tail end of the roll is pulled off the core.
    • This allows easily splicing the start of a new roll to the tail of the last roll, avoiding rethreading the sheeter at the decurler, slitters, delivery and stacker
    • A flapping tail at the end of the run can cause a jam up in the sheeter or misalign up stream settings
  • Remove the expired core
    • For shafted roll stands:
      • First, use material handling equipment (hoists, fork lifts) safely
      • Cut end of web from core, leaving webs threaded into sheeter
      • If using chucks, remove non-brake side chuck and slide off core
      • Better, consider using air shafts instead of chucks
    • For shaftless roll stands:
      • Cut end of web from core, leaving webs threaded into sheeter
      • Open arms of roll stand and remove core
      • Load the new roll
  • Load the new roll
    • For shafted roll stands:
      • Chuck roll tightly against the chuck left on the brake side of the shaft,
        • Insures that the far side of the roll is always in the same place
        • Keeping the drive side common, reduces set up time in half
      • Carefully load shafted rolls
      • Splice the leading edge of the new roll to the tail of the web in the sheeter
    • For shaftless roll stands, regardless of the width:
      • Position roll between arms and chuck up roll on floor
      • Slightly raise the roll and position behind sheeter
        • Add scales or markings on the floor at the unwind location
        • Use this aid to position the rolls quickly for alignment
      • Splice the leading edge of the new roll to the tail of the web in the sheeter
  • Thread the web through the sheeter
    • Slowly jog the web into the sheeter, taking care not to break the splice
    • Insure that the splice is removed in the delivery system, so as not to be stacked in the pile
    • Once the new web is fed through the sheeter, run at minimum speed
    • Make final adjustments to align the webs to the previous width set up