Running flat-out fast

Polyethylene-film and flexible-packaging manufacturer The Britton Group regularly invests in the latest technology and has worked closely with Spain's Comexi Group for more than 10 years. Most recently, the Louth, UK, plant of Britton Merlin received a new-generation Compack2 duplex slitter/rewinder from Proslit—Comexi's manufacturing partner. Installed last December, it is the first Proslit machine to be purchased by the Britton Group.

“We had decided to move away from our previous slitter supplier,” explains Bob Jenkins, site engineering manager at Britton Merlin, “but before that, we conducted trials on a Compack2 with our own material. The performance criteria we laid down were fulfilled, but we also took into consideration the price of the machine, its delivery and our ongoing relationship with Comexi.” The machine was duly installed, and performance is said to have been exemplary. “This one slitter completely outperforms our existing machines,” Jenkins says.

The Britton Group ranks as one of the top 10 PE-film makers in Europe, producing more than 95,000 metric tons of cast and blown mono- and multilayer PE films annually. Britton Merlin specializes in collation shrink, form-fill-seal, fresh produce, construction and flame-retardant films.

The converter's new Compack2 regularly is run at its maximum speed of 1,600 fpm. “The only thing that holds us back,” adds Jenkins, “is the customer's particular requirements on rewound-roll width and diameter.”

In developing the Compack2, Proslit wanted to offer a performance equivalent to many larger machines currently on the market, so the system combines compact design with some interesting additional features. Foremost among these is the patented Advanced Linear Tracking system, which allows high accuracy levels on the final output roll tensions. The ALT system is fully automatic, with both lay-on rollers moving horizontally across the web through a double guided system installed on the frame.

In practice, Britton Merlin has found the system works very well. “The ability of the Compack2 to maintain a constant, even tension in our materials is far superior to any of our existing machines,” Jenkins says.

To help achieve high productivity, Proslit integrates several design features into the machine. A new fixed-height unwind accepts parent rolls up to 2,200 lbs, 40 in. in diameter and 33-65 in. wide. Proslit can supply a trolley if the roll is being loaded from pallets, a pallet truck or an overhead crane. The shaftless configuration adapts to the parent-roll width, and the design allows roll integration into the machine.

The compact design also permits good access to the slitting area and simultaneous slit methods (razor and shear). Rewind-core setups with laser adjustment and friction shafts with directional ball-bearing rings along the shaft all help the operator to mount the cores faster and accurately. “This, in particular, has really made a difference in reducing downtime and roll changing,” Jenkins says.