Narrow Web Integrity
20 February 2008
NARROW WEB INTEGRITY - WINE LABELS TO RFID
Running a successful business today is more challenging than ever before. Customers driven by the demands of their own business are obliged to constantly review and evaluate their own supplier base in an ever increasing need for faster, more reliable response, higher quality standards and more cost efficient solutions. Therefore the very survival and prosperity of a converter depends on the ability to build and retain relationships with their customers. In building a relationship with a customer the primary aim is to build ‘trust.'
A customer trusts a converter not to let him down, not to miss deadlines and not to produce an inferior product. Hunter Paterson, Product Manager for contact web cleaning technology specialist Teknek Ltd says: "Once that trust breaks down the business relationship between converter and customer (and his customer) is at an end."
Best available machines and good people minimise the risk that the narrow web converter will produce an inconsistent product or miss delivery times and thereby lose customer trust. However, as with all aspects of label printing, increased competition, narrower profit margins and greater end use demands compel the narrow web producer to be ever alert to ways to fine tune their operations to sustain maximum speed and efficiency - and keep ahead of the game.
Unfortunately though, narrow web converting can sometimes seem like a constant exercise in overcoming inconsistencies in product quality, the cause of which is often due to airborne and other forms of particulate contamination. Particulates may be generated during substrate manufacture, during processes such as slitting and even during material storage prior to printing. The resulting downtime and product waste impacts on profitability but more than that, customers confidence in his supplier can be hit hard if a product with blemishes is shipped out too often.
Consistency of quality is becoming critical throughout many narrow web segments. For example, when producing a wine label for a prestigious vineyard, the label needs to be a work of art contributing to the overall pleasurable experience of owning a fine wine. A label with a hickey or some other blemish undermines this experience, and may cause a potential purchaser to question whether the wine is worth the price
Maintaining the aesthetic qualities of a label or other product is one thing; in many instances though the need to keep a web clean and free from contaminants is essential in order to preserve functionality. In the printing of conductive inks for RFID and electronic related products such as circuit boards or in smart card production, medical devices and flexible packaging quality is paramount.
The MWC or Mini Web Cleaner is one of a number of contact web cleaner options available from Teknek. Designed to meet ultra-narrow web cleaning requirements, the MWC prevents contaminants from finding their way into the process, eliminating the need for re-working, the payment of penalties and product throwaway.
Configurable for small web sizes and slower speed quality focussed applications, the MWC offers multi-point cantilevered installation framework, allowing the cleaning modules to be transferred between host machines for contact cleaning flexibility. The slim profile - 75mm (3"), interchangeability and optimum cleaning for minimal capital outlay makes the MWC suitable for many reel-to-reel applications such as label printing, taper automated bonding, flexible circuit production and in-mold decoration.
For larger web widths (10" & upwards) and higher production speeds, the Teknek NWP is an additional option. The NWP is available in a variety of styles, either configurable for single sided cantilevered machines or for double sided machines and in five length variations. Systems are easy to install and are driven by the web, thus ensuring perfect line speed synchronisation. Integrated inline the NWP gives top flight cleaning performance using clear on clear stock, vinyl and standard label stock.
Used in conjunction with all the major print and value-added processes, the Teknek contact web cleaning concept is based on the use of an elastomer roller which runs in contact with the web, penetrating the boundary air layer, which non-contact methods cannot reach. The elastomer roller on the NWP (and MWC) removes all particles down to microscopic size, these contaminants, i.e. dust, hair skin, paint flakes, slitter debris, etc, are then immediately transferred to a reverse wound pre-sheeted adhesive roller, where they become permanently trapped. When the adhesive roll becomes saturated, the outer pre-sheeted layer is simply removed - exposing the next underlying adhesive sheet ready for use. A powerful anti-static system can be incorporated within the system to ensure dust or dirt is not re-attracted.