Thousands of converting professionals are expected to attend CMM International next month to “kick the tires” on new machinery and equipment. That means that six months or so from now, there's also likely to be a fresh crop of new printing presses, coater/laminators and cast- or blown-film extrusion lines ready to be installed in plants across the country.

Whether you're planning a machinery purchase for next year or next month, one of the most important aspects for the long-term successful operation of that investment—proper alignment during installation—can often be overlooked among the myriad details. The following Q&A outlines points to keep in mind.

Q: What should I expect from the machinery manufacturer?

A: Installation drawings and procedures along with electrical, compressed air and heat/chill water requirements should be provided when the new line's engineering is complete. Most converting lines run qualifying product at the manufacturers' facility and meet the agreed line speeds and specifications, prior to shipment.

Q: What is typically required throughout the installation process?

A: An outline of recommended documentation and procedures follows.

1. It is recommended that a 3D Mapping or Industrial Survey of your facility be performed to determine the exact machine location and placement of floor-alignment monuments. It's necessary to confirm the location of overhead obstructions, floor elevations and entry-door openings and paths to the installation location. By using the latest technology in optical instruments, a 3-dimensional frame or environment can be created around the installation site. This has many benefits, such as speeding up the layout process, finding obstructions and avoiding costly mistakes.
2. Establish foundation layouts with utilities using conventional optical alignment or 3-D methods.
3. Establish Machine Axis [centerline] and Baseline [control lines.] Then place brass monuments in the floor along both lines for future reference. See definitions below.
4. Establish the machine-line footprint or sole-plate layout using manufacturers' CAD dxf/dwg coordinates. This can quickly and easily be accomplished by a trained alignment technician using the latest industrial total station instruments taking advantage of sophisticated layout routines.
5. The unloading and handling of the machine-line sections along with the installation of any electrical or piping services should be performed by qualified and insured installers. Safety is always a priority.
6. The installers may chose to optically align and level the machine sections as they are set into place on the footprint. Some installers align and level after the machine sections are set in their relative position. In either case, optical aligning or leveling of the entire machine is essential to insure a quality installation. Most machinery makers require optical alignment.
7. Documentation of alignment at the end of the machine's installation is essential. In some cases, an independent third party may need to perform a survey and document alignment to confirm the installers' accuracy.

Q: Who will do the installation?

A: Some manufacturers provide their own installation teams as part of a turnkey project. Others use “authorized” or “certified” installers. In different circumstances, the converter taking machine delivery at its facility is required to obtain an installation crew. If the installers are not certified to perform the optical aligning and leveling (to within ±0.001-0.002 in. for every 12 in. of web width), then a qualified alignment technician should be contracted.

Q: Why should we establish a footprint, Machine Axis [centerline] and Baseline [control line], prior to the line installation?

A: The footprint provides the floor layout for the positioning of all components and stations. A Machine Axis provides a line down the center of the machine for all future references to a standard. The Baseline is a parallel offset line to the machine axis, usually on the operator's side. This base or control line is used for all future alignment surveys, especially to confirm the accuracy of a new roller, station, or section replacement or upgrade.

Failure to establish both the Machine Axis and Baseline at the time of install can create major headaches, including days or weeks of downtime after production issues develop. Machine Axis and Baselines can be accomplished by either conventional or 3-dimensional means.

Q: How can I minimize downtime and waste in the future?

A: Have an optical alignment with necessary corrections conducted of each entire converting-machinery line once a year. There are many variables that can affect machine performance. Proper alignment throughout the year will optimize performance by:

Reducing worn parts that need to be replaced from misalignment, such as rollers and bearings; as well as reducing poor-quality issues such as wrinkling and waste both in startup and production and related issues.

Increasing uptime, line speed and accuracy, and shortening startup runs. In addition, customer satisfaction will grow for a job delivered on time with high quality, solidifying long-term job orders through a positive reputation for the supplier.