PCT Engineered Slitter-Folder Rebuild - Manual

© 2007 PCT Engineered Systems LLC. All Rights Reserved
8700 Hillandale Road
Davenport, IA 52804
563.285.7411
FAX 563.285.7433
www.teampct.com
The Solutions Team
Slitter-Folder Rebuild
The Application
A large plastic film manufacturer needed to
improve the output of several of its slitter-
folders, and increase the quality of the finished
rolls with minimal disruption to production in the
finishing department. The end products,
Polypropylene and Polyethylene, are widely
used in the packaging and food industries.
Throughput on the machine had been
negatively affected by unavailable parts due to
the age of the machine. The outdated
equipment also made it impossible to
determine the amount of tension on the film,
which resulted in inconsistent machine
operation and roll properties.
The PCT Solution
PCT Engineered Systems’ solution included using custom winder control logic in an Allen-Bradley
PLC for controlling film tension. PCT also provided a complete electrical and mechanical rebuild
utilizing items listed in the box on the right.
Upon completion of the project, PCT was able to provide
the customer with correct tensions resulting in improved roll
quality at increased speeds. The new control system
allows the operators to store and recall customer specific
“recipes” for tension settings.
According to the customer,”…PCT contributed to a 30%
increase in production with a 25% reduction in rejects and
the operators love to run the machine (which is a real
victory!)”
This project solution was then applied to additional slitter-
folder retrofits for the customer, and helped develop an
ongoing team relationship between the two companies.
Machine Rebuild Items
• PLC enclosure
• Drive enclosure with new digital DC
drives
• PanelView touchscreen operator sta-
tion with machine diagnostic displays
• Unwind operator station
• Three new DC motors
• New idler rolls and load cells to di-
rectly measure tension
• Revised taper tension control allow-
ing operators to create a softer roll as
requested by their customers
• New base to mount the motors and
rewind frame, improving stability of
the machine