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Over the last few years, the converting industry has emerged as one of the most important aspects of the modern manufacturing world. The industry is dynamic with web converting at the forefront, ushering in a new age of material processing. Web converting is an important area of study for anyone who wants to learn more about how everyday products such as plastic bags, paper bags, paper cups, adhesive labels and so on are made.
What is Converting Industry?
The converting industry is an important subsector of manufacturing. The converting industry is mainly concerned with the process of changing raw materials into finished or semi-finished products that are usable through several processing stages. The term ‘converting’ implies a change of form and function, where materials are processed and turned into new products, for example, converting big rolls of paper into printed products or converting plastic films into packaging products. This industry is diverse and can be classified under packaging, labeling, hygiene products, and industrial uses and is a key player in the global supply chain.
What is Web Converting?
Web converting is a specialized segment within the converting industry. It was designed to handle continuous rolls of material, often referenced as “webs.” Web converting includes a number of processes employing various equipment like printing machines, slitters, die-cutting machines, coating machines, laminating machines and dryers. These converting processes change materials such as paper, film, foil and nonwovens into products with certain characteristics needed in various sectors. The key to web converting is to be able to integrate precision engineering with advanced technology to make the processes efficient and at the same time produce quality products.
Printing Processes
Printing processes play a significant role in web converting, as they add value by transferring text, images, or patterns onto materials. This adds aesthetics to the finished products, and also the functionality. Consider vibrant labels capturing attention on a store shelf. In web converting, widely used printing technologies are flexographic, rotogravure and digital printing. Flexographic printing is renowned for its speed and ability to handle large-scale jobs on diverse materials. Rotogravure printing provides high-quality, detailed images, ideal for projects requiring fine resolution. Digital printing offers flexibility, allowing customization without the need for extensive setup, making it perfect for short production runs or personalized items. Each method brings unique advantages, enabling converters to meet diverse industry requirements efficiently and effectively.
Laminating Techniques
Laminating is an important process since it contributes to improving the durability, aesthetics, and barrier properties of materials. Laminating defines the process of combining two or more layers of material, often a printed substrate with a protective film, to form a single composite. Grocery packs meant for munchies tend to remain out for a longer duration due to their effective lamination technologies. There are several laminating machines for different requirements, but thermal, wet, and dry lamination are the most common. Thermal lamination employs heat to join a number of layers, most suitable where a strong, clear finish is required. In wet lamination, the layers have adhesives sandwiched in between and is used where fast turnover of products is a demand. Dry lamination uses a pre-applied adhesive, usually activated by heat or pressure, optimal for lightweight materials.
Coating Processes
Coating in web handling involves applying a material layer to a substrate to enhance its characteristics, similar to laminating but focusing on surface treatment rather than bonding layers. This technique improves durability, appearance, and functionality, making products like UV-protected windows or glossy magazine covers possible. Techniques such as roll coating, gravure coating, and curtain coating each serve unique purposes. Roll coating ensures uniform coverage, gravure offers precision for intricate patterns, and curtain coating is non-contact, ideal for delicate surfaces.
Coatings are applied during various stages of web converting, typically after initial processing like printing or before final assembly. Coating involves the use of specialized machinery, often requiring precise control of temperature and chemistry to ensure even application. Once applied, coatings often require drying or curing to solidify and adhere properly, ensuring the product’s longevity and performance.
Slitting Techniques
Slitting is the process of slicing a large roll of material into manageable, narrower strips, often with rewinding for easy handling and varied lengths. By manipulating the web material through a slitter, industries like labels and tapes—where precise widths are essential—can obtain materials that meet specific size requirements. Typically, larger rolls are produced initially for efficiency, and slitting maximizes material utility while minimizing waste. Slitting techniques like razor slitting, shear slitting, and score slitting are commonly employed. Razor slitting is optimal for thin materials, shear slitting provides clean cuts for thicker substrates and score slitting suits paper products. Accurate slitting relies on consistent tension control to prevent material deformation or misalignment. Before starting, operators should meticulously calibrate equipment to ensure an accurate and efficient process.
Die-Cutting Processes
Die-cutting involves stamping out specific shapes from web materials, playing a crucial role in product shaping across packaging, labels, and specialized industrial applications. Different machines are used depending on the pattern or design requirements. There are several types of die-cutting processes, such as rotary, flatbed, and digital die-cutting. Rotary die-cutting is ideal for high-volume production, offering speed and efficiency. Flatbed die-cutting is best for detailed and intricate designs, while digital die-cutting provides flexibility and customization without the need for physical dies.
Drying Techniques
In every printing, coating, and adhesive application process, there is an important stage – drying. It enhances adhesion and also ensures that the quality and effectiveness of the final product are not compromised. A collection of methods is used depending on the materials as well as the particular needs. Air drying is cost-effective and suitable for general applications with less time sensitivity. Infrared drying offers quick, uniform heating, ideal for thicker coatings. UV curing is efficient for rapid processing, providing instant results and is perfect for high-speed applications.
Perforating Techniques
Perforating involves creating small holes in a material to allow it to tear easily along a predetermined line or to facilitate breathing or fluid flow in applications like packaging or textiles. This process is particularly important in industries such as food packaging, medical textiles, and toilet paper manufacturing, where specific tear properties are required.
There are several types of perforating techniques, including needle perforating and laser perforating. Needle perforating is a traditional method that involves physical puncturing, often used in thicker materials. Laser perforating, however, provides clean and precise holes, allowing for programmable patterns and even micro-perforations in delicate materials.
Embossing Processes
Embossing is a process of giving a raised surface to the material by making designs or patterns on the surface of the web materials. This technique is widely applied in the improvement of product appearance and performance in packaging, marketing materials, and security applications. Heat embossing and blind embossing are two types of embossing that are used depending on the material to be worked on and the intended result. Heat embossing is a process that uses heat and pressure to give plastics and textiles such as fabrics a rich and textured look. The blind embossing technique that does not require ink or foil enhances the delicateness of printed items.
Hot Stamping
Hot stamping is a special process of applying metallic or colored foils to the web material. It employs heat and pressure for a strong and accurate result. Common in packaging and labeling, this process produces good visual effects which improve the looks and the recognition factor of products. Hot stamping is used in web converting to provide fine and bright details that cannot be achieved by other processes. The choice of foil, whether metallic, holographic or pigmented allows manufacturers to create designs that meet the expectations of the target market.
Adhesive Application
Adhesives are used on substrates to allow material bonding or joining. It has uses in many industries such as providing extra layers in packaging, securing labels and making different types of tapes.
Some of the adhesive technologies include pressure-sensitive adhesives, heat-activated adhesives and solvent-based adhesives. Pressure-sensitive adhesives bond immediately when pressure is applied to them, suitable for use in labels and tapes. Heat-activated adhesives need heat to activate them and are commonly used in textiles and automobiles. Solvent based adhesives that provide strong and durable bonds are used in more severe industrial applications.
Materials Used in Web Converting
Web converting involves a diverse range of materials, each influencing the process from machinery setup to the final product’s functionality. Here’s a look at common materials and their characteristics:
| Material | Characteristics | Applications |
| Laminates | Durable, strong | Packaging, protective films |
| Films | Flexible, transparent | Labels, flexible packaging |
| Paper | Sustainable, printable | Packaging, printing |
| Foil | Barrier properties, reflective | Food packaging, insulation |
| Nonwovens | Breathable, absorbent | Hygiene products, medical use |
| Textiles | Durable, versatile | Apparel, industrial use |
| Plastics | Moldable, lightweight | Bottles, containers |
Trends of Web Converting Industry
Increasing demand for eco-friendly products has contributed to a gradual increase in sustainability and environmental responsibility among participants in the web converting industry. There’s a clear shift toward using sustainable materials and processes that minimize waste and enhance efficiency. The adoption of technology is yet another great trend as automation helps to enhance quality and reduce the downtime for production processes. Automated systems provide control accuracy, providing production lines that are more economical and reproducible outcomes.
Conclusion
The web converting industry is situated at the heart of contemporary manufacturing whereby it offers a more enabling environment for product creation and innovation. Thanks to processes like printing, laminating, coating and slitting, the industry is able to present satisfactory solutions to the varying requirements of varying industries. By understanding these processes, professionals can harness the potential of web converting, pushing the boundaries of what’s possible.
Partner with KETE for Advanced Converting Machinery
KETE is a leading manufacturer of high-quality flexible printing and packaging converting machines. Their comprehensive range of web converting equipment caters to various industries, offering customized solutions tailored to specific client needs. These machines are designed to enhance production capacity, improve efficiency, and ensure superior product quality. KETE is committed to delivering exceptional customer service, providing support and expertise at every stage of the process. From consultation to installation and maintenance, their team ensures that clients receive not only top-notch machinery but also a seamless experience that maximizes operational success. Partnering with KETE means investing in reliable technology and ongoing support.
