Built for end applications: How slitting and rewinding machines can be "tailored" to materials.

The core value of the slitting and rewinding machine for end applications is to realize the "tailor-made" of materials. This is not just a simple reduction of large coils of material, but a systematic project integrating precision machinery, intelligent control, and process know-how.

Below we break down how the slitting rewinder achieves this goal:

Core concept: from "production-oriented" to "application-oriented"

In the traditional concept, slitting and rewinding is the last process of production. The modern concept is that slitting and rewinding is a "customized service center" to meet the needs of terminal applications. Its goal is to convert the master roll into the most applicable, efficient, and low-loss finished roll according to the customer's final use case.

Realize the four key technical links of "tailor-made"

1. Precise slitting: determining the "contour" and "quality" of the material

This is the first step in customization, ensuring that each material meets the dimensions and edges.

• Slitting method selection:

◦ Blade slitting: suitable for soft materials such as film, paper, non-woven fabrics, etc. By precisely controlling the angle and pressure of the blade, clean cuts are achieved and burrs and dust are avoided.

◦ Shear and slitting: Suitable for harder or thicker materials, such as rigid plastic sheets, metal foils, and composite materials. The upper and lower knives are matched like scissors, with high cutting accuracy and flat edges.

◦ Laser slitting: The highest-end non-contact slitting for highly sensitive materials (e.g., carbon fiber, flexible circuit board FPC) or where extreme precision is required. No tool wear, extremely fine cutting seams, no mechanical stress.

◦ Selecting the most appropriate slitting method according to the material characteristics is the key to ensuring the edge quality of the end product.

• Slitting Accuracy Control: The high-precision servo motor and tension control system ensure that the width tolerance of each material during the slitting process is stable at ±0.1mm or even less, meeting the demanding requirements of precision electronics, medical and other industries.

2. Intelligent rewinding: controlling the "intrinsic state" of the material

Rewinding is not just about rewinding, it determines the internal structure of the finished roll, which directly affects the production efficiency of the end customer.

• Tension Precision Control: This is the "soul" of the rewinder.

◦ Constant Tension Control: Maintain stable tension throughout the coil diameter change process to avoid material strain or wrinkling.

◦ Taper tension control: gradually decreases tension as the roll diameter increases. This is essential for soft, stretchable materials such as PE protective films to prevent "daisy patterns" and crushing of the inner layers, ensuring consistent coil tightness and easy unwinding on high-speed automatic machines.

◦ The end application determines the tension policy. For example, label materials require very precise taper tension to ensure that labels do not fly or break due to uneven tension.

• Rewinding mode selection:

◦ Center coiling: Simple structure and suitable for most general-purpose materials.

◦ Surface coiling: The material is pressed tightly against the coil core by pressing the roller, which can provide greater winding force, suitable for heavy materials or occasions where extremely tight winding is required.

◦ Center/surface winding: Combining the advantages of the two, it is an advanced way to achieve high-quality rewinding by using center winding to ensure accuracy when the coil diameter is small, and surface winding to ensure tightness when the coil diameter is large.

• Correction System: The Automatic Guidance System (EPC) ensures that the material always runs along the correct path during slitting and rewinding, preventing uneven slitting and crimping caused by misalignment.

3. Online Detection and Data Management: Provide "Eyes and Brain" for Customization

Modern slitting rewinders are no longer "blind cutting".

• Visual inspection system: Detect surface defects such as scratches, stains, holes, etc. of materials in real time during the slitting process. The system can mark defect locations and even automatically reject them during rewinding, ensuring that every meter of material delivered to the end customer is qualified.

• Intelligent control system: Based on PLC and HMI (human-machine interface), operators can preset and store process parameters (such as tension curve, slitting size, speed, etc.) of countless products. When switching products, the corresponding recipe can be called with one click, which greatly reduces the adjustment time and human error, and realizes quick order change.

• Data Logging and Traceability: The machine records the key production data (length, width, tension curve, etc.) of each roll of finished products and generates a unique "identity ID" to facilitate quality traceability and management.

4. Humanized design and accessories: meet special "application scenarios"

• Automatic tool change system: For production lines that require frequent changes in slitting specifications, the automatic tool change system can greatly improve efficiency and ensure tool change accuracy.

• Labeling and edge banding function: Automatically apply labels or edge banding at the beginning or end of the coil, which is convenient for customers to identify and use.

• Dust Removal/Cleaning Device: Cleaning materials before and after slitting, especially for applications with high cleanliness requirements, such as optical films and electronic materials.

"Tailor-made" in specific end use cases

1. Smartphone industry chain (OCA optical adhesive, protective film):

◦ Requirements: ultra-high cleanliness, clean room environment, no scratches, no static electricity, no glue spillage at the slitting edges.

◦ Customized scheme: Laser slitting or super-fine blade slitting, equipped with ion air rod to remove static electricity, the whole machine adopts oil-free design, and runs in the 10,000-level dust-free workshop.

2. New energy batteries (separators, pole pieces):

◦ Requirements: The material is extremely thin and easy to stretch, there can be no metal dust pollution, and the tightness of the coil is extremely high.

◦ Customized scheme: Adopt high-precision taper tension control, use ceramic blades or special tools to avoid metal pollution, and strictly control the hardness (HS value) of the coil during rewinding.

3. Medical packaging (dialysis paper, laminated film):

◦ Requirements: To ensure the sterile barrier performance of the material, the slitting edge must be sealed and free of burr dust.

◦ Customized solution: Hot knife slitting is used to heat seal the edges while cutting to prevent fiber shedding and ensure cleanliness and sterility.

4. Flexible packaging printing (BOPP, PET film):

◦ Requirements: High speed and efficiency, neat winding, adapting to the unwinding requirements of high-speed printing machines.

◦ Customized solution: High-speed model equipped with a powerful center/surface winding mechanism to ensure the quality of winding under large coil diameters.

summary

The slitting rewinder realizes the "tailor-made" of materials, and is a system solution that goes from "physical size" (width, diameter) customization to "intrinsic quality" (tension, hardness, edge quality), and finally serves the "end-user experience" (ease of use, high efficiency, low loss).

It is no longer a simple processing equipment, but an intelligent bridge connecting material production and terminal applications, through precise process control and data management, a roll of ordinary masterbatch is transformed into a "key component" that can perfectly adapt to specific machines and specific scenarios, truly reflecting the integration of "craftsman spirit" and "intelligent technology" in industrial manufacturing.