In today's competitive tissue converting environment, your slitting rewinder isn't just equipment—it's a revenue-generating asset. Modern maintenance has evolved beyond fixing failures: it's about predictive intelligence and systematic prevention.
Precision Blade Management
Dull or misaligned blades don't just create ragged edges—they generate micro-dust that contaminates electrical systems and increases web breaks by 300%.
Action Protcol
- Daily: Visual inspection for edge quality and dust accumulation.
- Weekly: Detailed tungsten carbide blade inspection with magnification.
- Monthly: Measure blade wear with precision gauges (replace when <80% original thickness).
Expert Insight
Implement blade rotation scheduling based on linear meters processed, not just time intervals.
Closed-Loop Tension Control
A 1% deviation in tension can reduce production yield by 5% over a shift through core crushing, telescoping, and interleaving defects.
- Weekly: Verify PLC receiving clean, noise-free signals.
- Monthly: Verify closed-loop feedback response time (<50ms industry standard).
- Quarterly: Professional calibration of load cells.
High-Speed Bearing Lubrication
Bearing failure is the #2 cause of unplanned downtime, yet 60% of premature failures are lubrication-related.
- Daily: Infrared temperature checks on main drive bearings.
- Weekly: Manual lubrication of non-automated points.
- Critical: Use ONLY manufacturer-specified NLGI Grade 2 or 3 lubricants.
Industrial Dust Control
The Invisible Threat: Tissue dust infiltration causes 40% of intermittent PLC failures and is the leading cause of photoelectric sensor malfunction.
- Daily: Blow out electrical cabinet cooling fans with clean compressed air.
- Weekly: Inspect air filter elements (replace when pressure drop >2x baseline).
- Best Practice: Maintain slight positive pressure in electrical cabinets.
PLC Diagnostics & Health
Your rewinder's control system is its nervous system. Electrical failures cause 25% of unplanned stoppages.
- Check for motor torque anomalies or inverter frequency spikes.
- Inspect contactors for carbon buildup monthly.
- Thermal imaging scan of electrical panels quarterly.
Industry 4.0 Tip
Modern systems can monitor motor current signature analysis to predict mechanical problems before they cause electrical failures.
Quick Troubleshooting Reference
| Symptom | Likely Cause | Immediate Action |
|---|---|---|
| Ragged Edges | Dull blades / Pressure | Check sharpness & pneumatic pressure |
| Core Crushing | Excessive tension | Reduce tension 10-15% |
| Web Breaks | Alignment Issues | Verify dancer arm & path |
| Motor Overheat | Bearing drag / Vent | Check bearings & cooling fans |
The Bottom Line
Companies with structured maintenance programs report a 40-50% reduction in unplanned downtime. Protecting your investment through disciplined maintenance is essential for long-term profitability.