Web guiding system boost precision

McCluskey, Laura -- Converting Magazine, 5/1/2000

When it added a new slitter/rewinder, Genesis Converting also had to find a web guiding system capable of meeting demanding tolerances.

Genesis Converting Corporation, Itasca, Ill., a rapidly growing converter, has built a reputation in the industry for seeking the most demanding converting projects. "We are not a company that backs away from a challenge," explains Genesis president Stan Budzinski. "However, we have a careful, systematic approach. We want to make sure before taking a project that we are capable of delivering to our standards what our customer is seeking, both from a production and scheduling standpoint. We have built our business by delivering what we promise."

That's no easy task for a company catering primarily to the medical/pharmaceutical trade. "It seems that packaging, although an important element in bringing a product to market, is almost always among the last things to be considered," says Budzinski. "Therefore, situations often develop in which very quick turnaround of packaging is required to meet a product release or distribution deadline."

Technology's deeper meaning

"It means we have to be very responsive to the demands of the marketplace," Budzinski explains. "Otherwise, we get left behind. Rather than have that happen, we at Genesis have made the commitment to put service and performance above every other issue."

Genesis routinely examines every facet of the production process and every procedure in its service policy, from order-taking through distribution and follow-up. And, it was this process that prompted Genesis to overhaul the way it approached web guiding. The converter's primary product is paper, poly or poly-foil pouches and roll stock.

"When you consider all the areas of our converting process, it would seem that web guiding would be a relatively simple part. We had just upgraded our machinery by adding a new Dusenbery 835 slitter/rewinder. Our production capacity increased tremendously, but are production precision still wasn't where I wanted it."

The problem, says Budzinski, was the edge guide that came as standard equipment on the slitter/rewinder. "We weren't getting close to accuracy I felt we had to have in order to do the kind of work we were seeking," he says. "And I knew we had a job coming that we just could not handle with the tolerances we were getting."

Extremely precise demands

Working through the distributor of the slitter/rewinder system, Genesis contacted Erhardt + Leimer, Inc., the South Carolina-based manufacturer of web process control systems.

"In essence, Genesis needed a web guide capable of extremely precise control, which is best found in a line sensor," says Dan Caruana technical salesperson of Erhardt + Leimer. "But they needed the versatility of being able to switch between line and edge guiding without much time for changeover."

After a review of options, Genesis chose E+L's FE 5001 Color Line Sensor. The sensor would cut their changeover time to a fraction of what it used to be, says Budzinski. It would function as both line and edge guide. The cost savings in changeover alone would create a significant opportunity for Genesis to offer value to its customers.

According to Caruana, the FE 5001 is, the latest in a line of high-technology digital sensors from E+L. Both the sensor and the actuator are fully digital. The FE 5001 can guide from lines, intermittent lines or color repeats. As Genesis has pointed out, it is exceptionally simple to set up and operate. It recognizes and remembers line size and color. It can guide from the edge or from the center of the web. And it can guide as close as .02 inches from the web edge or print.

Additionally, Caruana says the FE 5001 is sensitive enough to evaluate even the contrast caused by adhesive application. All settings for the FE 5001, such as switching from line to edge, can be easily set with the four keys on top of the sensor.

Two small fluorescent lamps, which are mounted on the sides of the housing, illuminate the surface of the material. A digital signal processor evaluates light reflected from the material and makes adjustments accordingly.

The actuator, as well, offers economies. Since it is an electric actuator and is digitally controlled, it enhances accuracy and eliminates the need for hydraulic fluid and costly maintenance of hydraulic power units.

"The versatility of the FE 5001 is its primary selling point for us," Budzinski says. "The bottom line is that it makes Genesis a company that can provide leading-edge capabilities to our customers, while maintaining the value of our products and services."

Genesis recently brought another Dusenbery 835 slitter/rewinder on-line. This time, the FE 5001 was specified as original equipment in the order.

"If a better solution comes on the market, we'll look at it," Budzinski says. "But at this moment, the FE 5001 from Erhardt + Leimer gives us flexibility, precision and value like no other web guide we've used."

In addition to the two Dusenbery slitter/rewinders, Genesis Converting also has two flexographic printing presses and eight pouch machines.

More information from:
Dusenbery, John, Co. Inc., 973/366-7500, fax: 973/366-7453, www.dusenbury.com
Erhardt + Leimer, Inc., 864/486-3000, fax: 864/486-3011.