Live Web Handling Fundamentals Workshop

Workshop Description

Web handling is a process engineering discipline focusing on improving productivity and reducing waste of product made from papers, films, foils, nonwovens, textiles, or any thin, continuous material.

Many manufacturing trends create new challenges for web handling and winding, including thinner or more delicate products, faster or more integrated processes, and ultra-clean or hazardous environments – all increasing the potential for web handling defects. Learning to handle these materials, processes, and environmental challenges will provide your company with a competitive advantage.

This three-day workshop will combine classroom seminars and lab demonstrations to cover key concepts to optimize your equipment and process designs; practical steps to eliminate waste from breaks, deformation, scratches, alignment errors, wrinkles, and roll defects; and lab demonstrations to see web handling principles in action.

Unlike any other option in web handling education, the Optimation MCF series of web handling ‘workshops’ are one-of-a-kind training that combines classroom seminars with on-machine demonstrations.

Notebook copies of training slides will be provided to attendees at the class. Snacks and lunch will also be provided each day. After completion of the class, a spreadsheet summarizing data collected during on-machine demonstrations will also be provided to attendees.

Who Will Benefit from this Workshop?

This workshop is directed towards the technical employees of any level with a need to understand the fundamentals of web handling. The only prerequisite is an aptitude for technology with an interest in the connection between theory and practice.

Web Handling Workshop Outline

The three-day workshop will aim for a 50-50 split between seminar and lab demonstration time.

Seminar presentations will include:

Web Mechanics and Tensioning

  • Why tension and how much
  • Web physical properties
  • Definition of a tension zone
  • Torque generation

Rollers and Traction

  • Roller basics
  • Roller alignment
  • Roller slip

Nipping Processes

  • Pressure within a nip
  • Nipped system design factors
  • Lamination best practices
Tracking, Wrinkling and Spreading

  • Perpendicular Entry Rule
  • Causes of web wrinkling
  • Web spreaders
  • Web guides

Winding

  • Winding key process variables
  • Roll pressures and stresses
  • Factors that facilitate roll winding

 Lab demonstrations will include:

Lab #1 – Web Mechanics and Tensioning

– Review of the tension control strategy on the Thin Web Rewinder (TWR)

– Measurement of web tensile properties

– Measurement of coefficient of friction

– Measurement of web camber

Lab #2 – Rollers and Traction

– Wiki stick for roller tramming and precision level for roller leveling

– Pi tape for total alignment and roll diameter measurement

– Micrometer for roller diameter measurement

– Dial indicator for roller run out

– Traction measurement using a hand-held Prony Brake on the TWR

– Traction measurement using the automated Prony Brake on the TWR

– Roller inertia and bearing drag

Lab #3 – Nipped Systems, Laminating

– Nip footprint and pressure measurement

– Strain matching and curl

Lab #4 – Wrinkling, Spreading, Guiding

– Perpendicular entry rule

– Web guiding demonstration

– Shear wrinkles due to misalignment on the TWR

– Spreader and anti-wrinkle comparison on the TWR

Lab #5 – Winding

– Wide web winding

– Low and high-speed winding

– Various methods of characterizing roll hardness

– Winding model predictions

Workshop Instructor

The workshop will be presented by Dr. Kevin A. Cole of Optimation Technology, Inc.

  • Dr. Cole, a Senior Web Handling Development Engineer with Optimation Technology Incorporated, has a PhD in Mechanical Engineering from the University of Rochester. Kevin developed his expertise in web handling over his 20+ years working for Eastman Kodak Company and led their internal training program on winding and conveyance process fundamentals. He was also an active participant in the OSU WHRC, including chairing their Industrial Advisory Board for four years. Kevin has a rare combination of excellent problem solving and modeling skills, allowing him to comfortably move between production and developmental work.

About the Workshop Facility

The Optimation Media Conveyance Facility (MCF) is a 5000-sq. ft. space featuring experimental, analytical, and limited production web handling capabilities for narrow and wide applications. The MCF, acquired in 2008 by OTI, has a 35-year history serving as an internal resource for Eastman Kodak Company, but is now available for commercial use, including serving as host for this workshop.

Workshop Fees:

Registration Fees          Early Registration Discount (3 weeks advance)

First registration:                  $1795                                                       $1625

Second registration:              $1720                                                       $1545

Third registration:                 $1645                                                       $1480

Bonus: Test Your Web and Roller

If you are interested in testing your webs or rollers, there is a limited space to do so during the workshop; however, contact us directly if you are interested in customized and confidential testing on a contract basis.

Bonus: ‘Test Your Web’ and ‘Test Your Roller’ During or After the Workshop

We offer the ultimate hands-on experience – testing your webs or rollers in any of the lab demonstrations.

Some ‘test your web’ work can be accommodated during the three-day workshop, but for more thorough or confidential testing, additional trials can be arranged for another time (earlier in the workshop week or a later date). Participants interested in the ‘test your web’ option should see the table below for more information on input web, roll, and core specifications.

In addition to testing your web on our standard and special rollers (please request information of what rollers we have), we also offer the option to ‘test your roller’ if you wish to understand traction, wrinkling, and spreading in a simulation that will best represents your process.

Customer-Supplied Roll/Web/Roller Requirements

Material plastic/paper/foil
Roll width 26 inches minimum, 56 inches maximum
Maximum roll diameter 26 inches
Minimum web footage 500 feet
Core material cardboard, plastic, metal
Core inside diameter 3.00, 6.00, or 8.00 inches
Core chucking Expandable
Core length web width to 58.375 inches
Web thickness 0.00025 to 0.010 inches
Minimum product bending radius 2 inches (minimum conveyance roller radius)
Test roller length face length minimum of 2 inches wider than web provided
  (59.5 inch preferred)
Test roller diameter 3.5 to 6.0 inches
Test roller mounting method dead shaft, 2 inch length each side,
by 1.378 diameter (+0.001, -0.001 inch)

live shaft, 2-inch length each side with a bearing OD of 1.378 (+0.000, -0.001 inch)

Web Handling Fundamentals Event Registration September 2021