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In the processing of roll materials, the duplex slitter rewinder has unparalleled importance. It stands out in the production as the silent operator who accurately and efficiently splits big rolls into smaller rolls as per the specifications of the subsequent processes. In this article, we will focus on this sophisticated piece of machinery so that you appreciate its worth and make the right investments.
What Is a Duplex Slitter Rewinder?
A duplex slitter rewinder is designed to longitudinally divide wide rolls of materials such as paper, film, or foil into narrow rolls, then rewind the latter onto new cores. Its distinctive feature is having two (or two sets of) rewinding stations. As one station is finishing the rewinding of a roll, the machine can switch quickly to the other station, which enables the control to start working immediately. This optimization solves most of the downtime caused by roll changes. In other words, these machines optimally suit operations which need continuous production with high efficiency.
How Does a Duplex Slitter Rewinder Work?
The working process of a duplex slitter rewinder typically includes these key steps:
- Unwinding: The wide parent roll is placed on an unwinding stand. Unwinding is often the slowest and hardest process, but modern equipment contains shaftless auto-loading systems which makes it a lot easier and faster. Web guiding systems like EPC have automatic tension control which keeps the material stable and inline before the slitting section.
- Slitting: The material passes through a certain set of knives such as rotary shear blades or razor blades and is divided into strips of the previously set width. Each material and required quality of the cut has its specific knife.
- Web Guiding: The slit narrow strips of material are guided by a precise roller system to different rewinding stations.
- Rewinding: The split materials are now spooled onto their fixed cores. In a duplex slitter, while one section is working, the other goes preps. In this manner, production is nearly constant. Each narrowly slit roll is maintained under streamlined tension, due to the use of differentially controlled rewind shafts, resulting in firm and even winding of the rolls.
- Trim Removal: Edge trim produced during slitting is usually removed by a blower fan or wound onto a separate trim winder.
The entire process is automated and precisely controlled. This ensures the final product meets strict quality standards.
Material Compatibility of Duplex Slitter Rewinders
Duplex slitter rewinders are known for their excellent material compatibility. They can process various flexible roll materials, including but not limited to:
- Paper: From thin paper to thick paperboard, including coated paper, kraft paper, thermal paper, etc.
- Пластиковые пленки: Various films used for packaging or industrial purposes, such as BOPP, PET, PE, CPP, PVC.
- Aluminum Foil: Aluminum foil used in food packaging, pharmaceutical packaging, etc.
- Non-woven Fabrics: Non-woven materials used in hygiene products, medical supplies, industrial filtration, etc.
- Ламинат: Flexible packaging materials made of multiple layers of material.
- Label Stock: Multi-layer composite materials commonly used in label production.
This broad compatibility means one duplex slitter rewinder can serve different production needs and industries.
Key Industry Applications for Duplex Slitter Rewinders
With their high efficiency and versatility, duplex slitter rewinders are essential in many industries:
- Flexible Packaging Industry: Used in food and beverage as well as personal care packaging products; serves in slitting composite films, plastic films, aluminum foil, etc.
- Полиграфическая промышленность: Involves slitting paper and label stock for subsequent printing or further processing steps.
- Бумажная промышленность: Involves slitting large rolls of paper to smaller rolls for commercial or industrial purposes.
- Производство фильмов: Involves slitting parent film rolls to customer specific finished roll sizes.
- Текстильная промышленность: Involves slitting non woven fabrics or other roll textile materials.
- New Energy Industry: Some precision duplex machines are able to slit lithium battery separators.
In these industries, it forms an integral section of the supply chain, integrating the raw material manufacturing processes with the final product assembly.
Key Advantages of Duplex Slitter Rewinders
When it comes to selecting a duplex slitter rewinder, there are compelling advantages for any business:
- High Production Efficiency: The duplex configuration reduces roll change downtimes, enabling near-continuous production for greatly enhanced output.
- Excellent Slitting Точность: Advanced tension control, web guiding systems, and high-quality knives ensure accurate slitting width and smooth, neat edges.
- Wide Material Adaptability: Duplex slitter rewinders are capable of processing different thickness and nature of roll materials, increasing the equipment’s versatility.
- Лучше Перемотка Quality: Uniformity of tightness and equality of flatness on the ends of the completed rolls are ensured by accurate control of winding tension as well as differential rewinding methods.
- High Level of Automation: The value of an expense decreases when the amount of manual work done, such as operating a machine that does automatic loading, automatic tension regulating and web guiding, increases. Thus, a machine with lesser manual operation has a better expense value ratio.
- Improved Безопасность: Equipped with safety fences, safety sensors, and other protective devices to ensure operator safety.
A combination of these advantages leads to automated systems that achieve higher efficiency in production steps, improved quality of goods produced, and reduced expenditure in operations.
Selection Guide: Find Your Ideal Duplex Slitter Rewinders
Choosing a duplex slitter rewinder that fits your production needs requires careful consideration of several factors.
Assess Your Production Needs
At first, identify materials you will predominantly process regarding types and specifications (material type, thickness, max/min width), finished roll specifications (minimum slitting width, maximum rewind diameter), and estimated output. This will outline the machine’s capabilities.
Match Machine Speed Required
The machine’s maximum mechanical speed is a key factor affecting output. Calculate the required slitting speed based on your target output and shift schedule. But remember, actual production speed is influenced by material properties, operator skill, and roll diameter changes.
Consider Material Handling Needs
The management of materials during unwinding and rewinding procedures is also very important. The parent rolls of great weight are best handled with shaftless auto-loading systems. As far as rewinding is concerned, the outer diameter of the completed rolls, the the inner diameter of the core, and the need for differential rewind shafts which process strips of different thickness and tension have to be considered.
Explore Available Configurations
Various types of configurations impact the efficiency and effective of the machine. Determine which knife cutting methods – rotary shear, razor blade, or score cut – best aligns with your materials. Understand the principles and limits of tension control systems. Evaluate the accuracy of web guiding systems. In addition, laser core placement, splice tables, trim waste winders, and camera inspection systems significantly improve operational efficiency and quality.
Evaluate Automation Level
More advanced automation, including automatic cutting, roll changes, and unloading, can significantly reduce the workload of an operator. Greater automation reduces an operator’s workload and minimizes idle time. This improves overall efficiency, especially for high-volume, long-run production.
Plan for Space and Budget
Finally, take into account the machine’s physical footprint and installation space along with your budget. Within the price range of your investment, ensure to get the machine which benchmarks best for performance, fully satisfies your requirements, and has good servicing options.
Top Duplex Slitter Rewinders to Boost Your Production Efficiency
Some types of slitting and rewinding equipment are well known for their reliability, efficiency, and versatility. These machines serve as a solid starting point for many processing industries to enhance their business capacity and the quality of products offered. Here, we will present some remarkable KETE models which are tailored for specific goals and challenges to have more value in production.
Founded in 2011, KETE has built a service network in over 80 countries and achieved an annual sales record of more than 2000 units. The company’s core employees have 40 years of experience working towards establishing systematic trust and reliability with clients. KETE collaborates with the top 3 internationally recognized factories in the industry. KETE’s core values—quality conscious, customer focus, innovation oriented, sustainability targeted, and honesty—are integrated from custom design to pre-sales and after-sales servicing. Their goal-aligned operational efficiency revolves around crafted systematic responsiveness and dependable service alongside crafted holistic solutions. KETE provides a warranty for 1–2 years on their equipment, which has electrical parts from Delta, Schneider, and Panasonic, which are recognized all over the world. System Integrators and Equipment Distributors in need of competitively priced machinery will find KETE advantageous for corporate collaborations and volume orders.
КТСМ-C600G
The KTSM-C600G Series is a sophisticated duplex slitter rewinder with unique capabilities for managing expansive rolls of paper. Much like a sprinter, it excels within the paper processing industry with a sprinting top speed of 600m/min. Its considerable capabilities include 3 servo motors, Germany E+L EPC systems, Siemens PLCs, etc, enabling flawless slitting and rewinding of paper jumbo rolls 100-500gsm into narrow web rolls. Unwind diameter is a maximum of Φ1600mm and rewind diameter a maximum of Φ1300mm. Customers looking for precise paper roll slitting without sacrificing efficiency will appreciate features like shaftless auto-loading, auto tension control, circular shear blade slitting, and self honing.
| Технические характеристики машины | KTSM-C600G/1800/2600 |
| Структура перемотки | Двусторонняя перемотка |
| Ширина сырьевого материала | 1800/2600 мм (71"/102,4") |
| Макс. Диаметр размотки | Φ1600 мм (63") |
| Макс. Диаметр перемотки | Φ1300 мм (51,2") |
| Мин. Ширина прорези | 30 мм (1,18") |
| Макс. Механическая скорость | 600 м/мин |
| Внутренний диаметр бумажного сердечника | 76 мм/152 мм (3"/6") |
| Техника продольной резки | Ротационный ножничный рез (пневматический) |
| Снятие обшивки | Вентилятор всасывания |
| Подача воздуха | 0,6-0,8 МПа (0,8 м³/мин) |
| Общая мощность | 95 кВт |
| Вес машины | 12000 кг |
| Размер машины (LWH)m | 6150x4600x2300 мм |
| Мощность машины | 5 линий 3 фазы 220/380/440V 50/60HZ |
КТСМ-C400G
The KTSM-C400G Series is a versatile duplex slitter rewinder. It is suitable for slitting and rewinding large jumbo rolls of various papers, adhesive stickers, films, or laminates into narrow web rolls. It is specially designed to meet the requirements of customers who want to get larger diameter finished rolls (up to Φ1500mm), meeting specific application needs. Like the C600G, it is equipped with shaftless auto-loading, EPC web guiding, and auto tension control, ensuring the quality of slitting and rewinding. The maximum mechanical speed is 400m/min. This machine is a reliable choice for many customers seeking to process multiple materials and requiring larger finished roll diameters.
| Технические характеристики машины | KTSM-C400G/1600/1800/2000/2600 |
| Структура перемотки | Двусторонняя перемотка |
| Ширина сырьевого материала | 1600-2600 мм (63"-102.4") |
| Макс. Диаметр размотки | Φ1700 мм (67") |
| Макс. Диаметр перемотки | Φ1500 мм (59") |
| Мин. Ширина прорези | 30 мм (1,18") |
| Макс. Механическая скорость | 400 м/мин |
| Внутренний диаметр бумажного сердечника | 76 мм/152 мм (3"/6") |
| Техника продольной резки | Роторные ножницы |
| Снятие обшивки | Вентилятор всасывания |
| Подача воздуха | 0,6-0,8 МПа (0,8 м³/мин) |
| Общая мощность | 56 кВт |
| Вес машины | 14000 кг |
| Размер машины (LWH)m | 8500x3500x2700 мм |
| Мощность машины | 5 линий 3 фазы 220/380/440V 50/60HZ |
KTSM-C600T
The KTSM-C600T Series is an innovative high-speed turret slitter rewinder. It smartly combines the capabilities of a duplex center winder with the productivity gains of a turret design. Using auto-splicing and cutting technologies, this machine significantly reduces downtime between sets, achieving extremely high production efficiency. It is particularly suitable for high-speed slitting of label stock and flexible packaging. Its maximum mechanical speed can reach 600m/min and offers shear or razor blade slitting options. It is a powerful tool for production environments pursuing ultimate efficiency and automated roll changes, like a skilled magician completing roll changes in the blink of an eye.
| Технические характеристики машины | KTSM-C600T/ 1100 | KTSM-C600T/ 1300 |
| Структура перемотки | Перемотка с двумя турелями | Перемотка с двумя турелями |
| Макс. Ширина сырьевого материала | 1000 мм (39,4") | 1200 мм (47,2") |
| Макс. Диаметр размотки | Φ600 мм (23,6") | Φ600 мм (23,6") |
| Макс. Диаметр перемотки | Φ450 мм (17,7") | Φ450 мм (17,7") |
| Мин. Ширина прорези | 50 мм (1,97") | 50 мм (1,97") |
| Макс. Механическая скорость | 600 м/мин | 600 м/мин |
| Внутренний диаметр бумажного сердечника | 76 мм/152 мм (3"/6") | 76 мм/152 мм (3"/6") |
| Техника продольной резки | Лезвие бритвы в воздухе | Лезвие бритвы в воздухе |
| Снятие обшивки | Вентилятор | Вентилятор |
| Подача воздуха | 0,6-0,8 МПа (0,8 м³/мин) | 0,6-0,8 МПа (0,8 м³/мин) |
| Общая мощность | 15 кВт | 18 кВт |
| Вес машины | 4000 кг | 4200 кг |
| Размер машины (LWH) | 2200x4000x2100 мм | 2200x4300x2100 мм |
| Мощность машины | 5 линий 3 фазы 220/380/440V 50/60HZ | 5 линий 3 фазы 220/380/440V 50/60HZ |
KTSM-C400L
The KTSM-C400L Series is a duplex slitter rewinder designed specifically for flexible packaging materials like PET, BOPP, CPP, PE, PVC film, and paper. With a 3-motor drive system, it aims to provide good quality finished rolls with smooth edges. It can also meet the requirements of customers who want to get larger diameter finished rolls (up to Φ800mm). The maximum mechanical speed is 400m/min. It is equipped with shaftless auto-loading, EPC, and auto tension control, as well as shear or razor blade slitting options. It is a reliable machine for flexibly processing various film and paper materials.
| Технические характеристики машины | KTSM-C400L/ 1300 | KTSM-C400L/ 1700 |
| Структура перемотки | Двусторонняя перемотка | Двусторонняя перемотка |
| Макс. Ширина сырьевого материала | 1200 мм (47,2") | 1600 мм (63") |
| Макс. Диаметр размотки | Φ1800 мм (70,8") | Φ1800 мм (70,8") |
| Макс. Диаметр перемотки | Φ800 мм (31,5") | Φ800 мм (31,5") |
| Мин. Ширина прорези | 30 мм (1,18") | 30 мм (1,18") |
| Макс. Механическая скорость | 400 м/мин | 400 м/мин |
| Внутренний диаметр бумажного сердечника | 76 мм/152 мм (3"/6") | 76 мм/152 мм (3"/6") |
| Техника продольной резки | Роторные ножницы | Роторные ножницы |
| Снятие обшивки | Вентилятор | Вентилятор |
| Подача воздуха | 0,6-0,8 МПа (0,8 м³/мин) | 0,6-0,8 МПа (0,8 м³/мин) |
| Общая мощность | 12 кВт | 15 кВт |
| Вес машины | 3800 кг | 4000 кг |
| Размер машины (LWH) | 2200x4000x2100 мм | 2200x4300x2100 мм |
| Мощность машины | 5 линий 3 фазы 220/380/440V 50/60HZ | 5 линий 3 фазы 220/380/440V 50/60HZ |
KTSM-C100
The KTSM-C100 Series is a compact and practical duplex slitting machine. It is designed for slitting non-printing roll materials like non-woven fabrics, BOPP, PVC, etc., into small-size rolls. It features a duplex rewind structure and air shafts. It can slit large parent rolls into small finished rolls. Although the maximum mechanical speed is 100m/min, lower than high-speed models, it includes an EPC system and razor blade slitting. It is also compact and has low power consumption (2.2kw/3.0kw) and weight (500kg/800kg). For specific materials and smaller scale slitting needs, it is a cost-effective and easy-to-operate option.
| Технические характеристики машины | KTSM-C100 / 1800 | KTSM-C100 / 2600 |
| Структура перемотки | Двусторонняя перемотка | Двусторонняя перемотка |
| Макс. Ширина сырьевого материала | 1600 мм (63") | 2400 мм (94,5") |
| Макс. Диаметр размотки | Φ800 мм (31,5") | Φ800 мм (31,5") |
| Макс. Диаметр перемотки | Φ450 мм (17,7") | Φ450 мм (17,7") |
| Мин. Ширина прорези | 50 мм (1,97") | 50 мм (1,97") |
| Внутренний диаметр бумажного сердечника | 76 мм/152 мм (3"/6") | 76 мм/152 мм (3"/6") |
| Макс. Механическая скорость | 100 м/мин | 100 м/мин |
| Техника продольной резки | Лезвие бритвы в воздухе | Лезвие бритвы в воздухе |
| Снятие обшивки | Вентилятор | Вентилятор |
| Подача воздуха | 0,6-0,8 МПа (0,8 м³/мин) | 0,6-0,8 МПа (0,8 м³/мин) |
| Мощность машины | 2,2 кВт | 3,0 кВт |
| Вес машины | 500 кг | 800 кг |
| Размер машины (LWH) | 1800×2000×1000 мм | 2000×3200×1200 мм |
| Мощность машины | 5 линий 3 фазы 220/380/440V 50/60HZ | 5 линий 3 фазы 220/380/440V 50/60HZ |
Duplex Slitter Rewinder Maintenance: Expert Tips and Tricks
Proper maintenance of your duplex slitter rewinder is key to ensuring its long-term stable and efficient operation, maximizing the benefits of duplex slitting machine. Here are some expert tips:
- Regular Cleaning: Regularly clean dust, paper scraps, and adhesive residue from the machine, especially near knives, guide rollers, and tension sensors.
- Knife Maintenance: Regularly check the sharpness of the knives. Regrind or replace as needed to ensure slitting quality.
- Lubrication: Follow the manufacturer’s guide for regular lubrication of moving parts, bearings, and drive chains.
- Tension System Check: Regularly check the accuracy of tension sensors and control systems to ensure stable tension.
- Web Guide Calibration: Regularly check and calibrate the EPC web guiding system to ensure material runs straight.
- Безопасность System Check: Regularly test the function of safety fences, emergency stop buttons, and safety sensors.
- Electrical System Check: Have qualified personnel regularly inspect electrical connections and components to prevent potential faults.
- Техническое обслуживаниеЖурнал: Keep a detailed maintenance log, recording the date, content, and problems found for each maintenance task.
Prevention is better than cure. Careful maintenance can effectively avoid sudden failures and extend the equipment’s lifespan.
KETE: Reliable Duplex Slitter Rewinders Backed by Expert Support
Choosing KETE means not just buying a slitter rewinder, but also choosing a partner with deep industry experience and a global service network. KETE ensures equipment reliability and consistency through high standards of quality control (ISO 9001, CE certification, some RoHS) and cooperation with top 3 factories. Their strong customization capability allows them to provide personalized equipment solutions based on your specific material and production needs, offering one-stop equipment configuration from printing and laminating to slitting and bag making.
KETE’s strengths lie in their commitment to quality, customer-centric philosophy, and continuous innovation. They provide transparent production progress updates, ensuring safe and fast delivery of equipment. They offer professional consulting pre-sales, visual information during production, and a 1-2 year warranty after-sales. Engineers are ready to provide on-site installation, training, and troubleshooting services when needed. Furthermore, spare parts support for common wearing parts and online system upgrades for most machines ensure your equipment always operates at its best performance, maximizing your return on investment.
Заключение
The duplex slitter rewinder is an indispensable high-efficiency equipment in modern roll material processing. Understanding its working principle, advantages, and how to choose based on your own needs is key to improving production efficiency and product quality. With this guide, and by considering suppliers like KETE who have reliable strength and a complete service system, you will be able to find the duplex slitter rewinding solution best suited for you, injecting continuous momentum into your business.
