For years, turret slitting machines were considered the mark of high productivity in the converting industry. The logic was simple enough: while one shaft was doing the winding, the operator could unload finished rolls and prepare new cores on the other shaft. This way, the machine was effectively in production.
Today’s safety regulations prevent this mode of operation. To work on the non-winding shafts whilst the machine is running requires both the speed and torque of the winding shafts to be limited to such an extent it is as if the machine is stopped. Universal Converting Equipment believes that the safety regulations have been put in place for a good reason and they should be adhered to and not ignored. Ultimately, the best way to make a process safe is to remove the need for an operator to undertake work that carries a risk. The Universal X8 Slitter Rewinder uses automation to load and position cores, unload and close rolls plus restart the machine after finished roll removal; all without operator intervention.
Although this automation was developed to make a turret slitter safe to operate efficiently, in tests it made the duplex slitter so productive it had little value adding it to a turret machine. The smaller footprint and ease of operation of a duplex machine more than compensated for potential benefits of a turret machine.
Mastering the Web: From Narrow Precision to Wide Web Power
Whether converting on narrow web applications such as bottle labels and complex laminates or running wide web, high speed industrial substrates, all converters struggle with material property variation.
- Narrow Web Excellence: In narrow slit configurations, even the smallest fluctuation in tension or nip pressure is magnified, frequently causing telescoping, poor separation, or reel instability.
- Wide Web Integrity: For wide-format applications, maintaining uniform tension and contact roll pressure across the entire web is critical to prevent the edge deformation, corrugation, or internal stress patterns that compromise downstream performance.
At Universal, we solve these issues by starting every project with a “clean sheet of paper”. On the Universal X8, we achieve elite-level control by monitoring tension at three critical points: the unwind, the slitting zone, and the rewind. This creates a high-speed, closed-loop mechanism where the tensions and pressures are regulated in real-time.
Meet the Universal X8: How We Flipped the Script on Productivity
It’s clear that we needed to start thinking about the problem differently, which resulted in the creation of the automated Universal-X8. Through implementing a process whereby no operator ever needs to approach the machine while it’s operating, we’ve been able to create a level of both safety and efficiency that is unmatched by any turret machine.
This is possible thanks to our “Zero Touch” automation, which goes above and beyond just slitting:
- Fully Automated Core Management: The use of dual positioning arms enables fully automated loading and positioning of cores without any mistakes.
- Safe and Precise Cutting: In order to remove the hazard of sharp knives, all of our rotary shear and razor blades are positioned precisely and can be moved to the side during threading. Both the razor and male shear holders can be removed by undoing one screw and replaced without affecting the position. The razor holders also have a position where the blade where it is fully enclosed removing any cut hazard without the need for the operator to make safe by removing the blade.
- Automatic “Recipes”: All the key parameters for each material are saved in recipes. Not only does this include tensions and pressure but also shear knife depth and shear knife sideload. The depth and sideload of the knives is critical to good quality slitting. Both are automated on the X8 with micrometer feedback of the positions.
- ARX Robotics: For high volume production, an additional logistic issue can arise due to the quantity of rolls being produced. The ARX robot extracts rolls from the rewind shafts and transfers them to the conveyor system. This way, the whole process is tied into automatic weighing, internal/external roll labelling, bagging and robotic palletizing.
Taking the Physical Toll Off the Operator
This design goes beyond ensuring safety, it makes work easier for operators, too. Running production at 3280 ft/min (1000 m/min) is demanding, and the repetitive task of placing cores and lifting heavy rolls can quickly lead to fatigue or injury. With the X8 and ARX system taking over these physically taxing jobs, operators are protected from strain and can concentrate on more complex, skill-based tasks. Additionally, the Universal X8 sets up in just two minutes and uses closed-loop feedback to keep material tension consistent throughout the process.
Conclusion: Big Results, Small Footprint
The result is a machine that’s not only safer but also easier for people to operate and requires less space than turret slitting machines. Thanks to precise tension measurement and a smart duplex design, Universal Converting Equipment shows that the future of converting isn’t just about making things faster. It’s about how intelligently the machine can work for you.
