Two of the most pressing challenges of traditional flying splicing in flexographic printing are the need to reduce printing speed and the inconsistent performance of the splice which can lead to failures and production downtime.
A new splicing tape developed by adhesive tape specialist tesa overcomes these issues and enables fast and easy splice preparation with reliable results while eliminating the need to reduce printing speed. Called tesa EasySplice FilmLine PLUS the tape is designed specifically for use with the latest generation flexo print films and facilitates automatic roll changes.
Cost pressures and moves to reduce packaging waste have spawned the creation of a new generation of thinner films which are more sensitive to tension in the film web during production. Concurrently the packaging industry is using extremely smooth films designed to optimise efficiency on ‘form, fill and seal’ systems and these are capable of gliding at high speeds. Online handling of these materials raises the bar for reliable splicing technologies.
Designated tesa 51910 the splicing tape has been rigorously tested on a broad range of substrates at web speeds of over 600m/min with convincing results. Roll changes can be performed with even the thinnest and most flexible films, such as the outer layer of nappies, without reducing web speed. Positive results have also been achieved when laminating printed films, in particular those with aluminium or other barrier layers.
Key to the success of the tape is the high tack of the split backing strip which provides the necessary adhesion for splicing film bales, including soft and loosely wound rolls.
In every case trials have shown it has been possible to increase the rate of successful flying splices without significantly reducing the speed compared with conventional splicing techniques. Constant web speeds produce consistent laminating results and reduce the amount of waste in downstream processes. These advantages combine to deliver cost savings.
Managers responsible for improving efficiency in printing shops have confirmed the financial benefits. One printer found his operators could prepare a simple, straight-line splice using just one tape - significantly reducing complexity at this crucial stage. Splicing speed increased to 480 metres per minute and this reduced web variation and improved productivity. Additionally the splice performance itself was increased. Failures were reduced almost to zero, while waste and downtime were cut. Less web variation occurred on the laminator due to the higher splicing speed and this allowed a narrower trim area and reduced film roll widths, leading to significant long-term cost reductions.
The bottom line is greatly enhanced reliability, quality and cost efficiencies throughout printing and laminating processes.
More info:
www.tesa.co.uk/tesa51910