Challenges in Winding Flexible Packaging Film, 2016 PLACE Conference

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Every flexible film producer is faced with the challenge of producing quality rolls of film products.  Since no film is perfectly uniform across its width, rolls of film must be wound so that these slight imperfections do not stand out in appearance and are not amplified during the winding process.

This paper addresses the importance of roll hardness and the proper profiling of roll hardness for consistently producing good quality rolls of flexible packaging films.  It then discusses the winding principles used on all winders to control in-wound tension or roll hardness. Rules of thumb are given to help determine the proper amount of web tension for various types of films.  Then the principles of nip and gap winding using controlled torque to produce the desired roll hardness are explained.  After the discussion of how roll hardness is achieved, methods of roll hardness measurement are presented.  Causes and remedies for many defects due to roll hardness are addressed.  Information on the new reference book The Ultimate Roll and Web Defect Troubleshooting Guide is presented to further assist in consistently producing quality flexible packaging films.