Case Studies

Double E is a solutions provider. The company engineers and applies its products with over 40 years of industry experience behind it, generating thousands of success stories. Please find a few examples of how Double E has helped customers below.

Maker of High Pressure Rubber Hoses Upgrades Braiding Machine with Narrow Web Stands

Double E worked with one of the largest hose manufacturer in the world that offers high pressure rubber hoses with wire braided sleeves often seen on industrial machinery and high end automobile engines. The company had a situation where they needed a way to control the feed of the liner material that is fed between the wire braid and the internal rubber hose. The line speed is very slow, 3 FPM at .5 pli with a roll diameter of 24" on a 3"core. The material needed to be regulated to eliminate any distortion and provide a constant even tension throughout the production process.

Initially the customer was using a basic stub shaft, with no tension control, to unwind the material. A device had to be engineered that would be flexible enough to easily mount to the production line, provide the right amount of tension, and provide quick roll change. The solution was a stand that consisted of a strip chuck mounted on a safety chuck body and regulated by a pneumatic brake.

The first device created for the customer was a prototype that featured an SR-2000 chuck combined with a Re CX-200 pneumatic brake. This device worked well but the customer realized that they wanted the flexibility to manually adjust the tension of the slow, low tension liner material. The second prototype featured the same SR-2000 chuck but used a slipper clutch to manually control the tension. This combination was good for running the linear material on the outside of the brader machine but when the customer installed a second roll stand within the machine, to hold the internal rubber hose, they soon discovered that it was difficult to maneuver the air hose around to activate the strip chuck. The device was then modified with an LC-1000 latching roller chuck which worked by simply twisting the chuck to lock the core in place. This solution provided the customer with quick roll changes without the use of any tools. 

The customer has since expressed how pleased they are with their new CBA-1000 roll stand and decided to use this same latching roller chuck/slipper clutch configuration for the outside of the braiding machine to handle the liner material. Double E and the customer have since negotiated outfitting all of their braiding lines with this configuration since the line operators have communicated just how easy this system allows them to change out rolls and make the necessary adjustments to line tension.

Double E's DF-2000 core chuck is used by the large majority of corrugators throughout the USA, and in fact, all over the world. It has been the industry standard for over three decades.

Recently, some corrugating plants have seen a degradation in core quality that has caused the cores to fail, even in normal operating conditions. To overcome the inherent weakness in these cheaper cores, Double E recommends its EHDL (Extra Heavy Duty Long) DF-2000 core chuck. It is a larger and beefier version of the standard chuck, but offers a contact patch area 40% larger. This difference allows the chuck to spread the torque over a greater surface area of the core to ensure normal processing.

An increasingly common story in the corrugating industry is exemplified by one Double E customer in Massachusetts. The maintenance manager at this particular plant was suddenly plagued by core tear-out problems after years of care-free operation. Slipping was making it impossible to run rolls to the last wrap, forcing slower machine speeds, and even leading to reduced board quality. The plant was losing money on wasted material and on wasted time. Thinking the problem was being caused by the Double E DF-2000 chucks that were installed on all of his machines, he called Double E to complain.

Double E worked with the customer to determine that the chucks were functioning properly. They had been working for over six years and were still in perfect mechanical condition. They hadn't changed, but something was wrong. Double E engineers tested the cores being used at the plant and found that they were thinner than usual and that they frayed easily. As it turned out, the core supplier had changed their process to reduce costs. The cores were thinner and did not meet the specifications necessary for normal processing. The core manufacturer wasn't going back to the old way, and more and more suppliers are following suit.

This corrugator, like many others, had to deal with this new reality of inferior core quality. Double E proposed its EHDL chuck. Its larger gripping jaws grip more of the core to minimize the chance of slipping. The customer purchased a pair of the larger chucks as a test, and saw the problem end immediately. They subsequently upgraded all of their roll stands, and have now returned to the care-free operation that they enjoyed previously.

If you're having problems with core tear out, you are not alone. Double E's Extra Heavy Duty Long DF-2000 core chuckcan help. Please contact the Double E Company for more information.

One of the largest wrapping paper makers in the country sought the help of Double E regarding core extraction issues they were having on one of their production lines. This line was using a turret winder with strip shafts. The line was running a combination of 3" and 6" cores. The machine's operator had trouble handling the 55-60 lbs. shafts when the rewound roll was removed from the press. Roll changeovers were taking a long time. The customer's primary pain for this application was concern for operator safety.

Double E provided the customer with two 3" PC-4000 Pneumatic/Mechanical Core Chucks and two 3"-6" Step Idlers for the PC-4000. One pair of each was mounted on each arm of the turret winder. The PC-4000 was chosen because the application requires a positive grip chuck. The rewind stops and starts frequent¬ly. Because both 3" and 6" cores are run on this printing line, Double E also provided the customer with two 3"-6" adapters for the PC-4000 chucks.

The chucks were installed in mid-2007 and have been working well since. According to plant engineer at the production facility, "the chucks are working great and roll pro¬cess time has improved. All safety issues have been resolved." Now, the operator does not need to remove a 60 lb. shaft during changeovers. Double E and the customer have converted a shafted turret winder into a shaftless turret winder. This conversion resulted in a safer, more efficient work environment.

Recently a flexible packaging converter that services the food, beverage, medical, and other specialty markets turned to Double E for help in increasing their capacity. The customer was trying to make a decision on whether to purchase a new slitter rewinder or simply upgrade their older machine. Pains they experienced with their setup included tension control problems, friction style differential rewind shafts that were difficult to maintain, and poor product support.

Tension Control Problems

The existing machine had a motorized unwind with dancer, s-wrap and rewind with ultrasonic sensor that previously had tension control upgrades performed over the years, but it was not working. The operator had to manually adjust the air pressure in the differential rewind shaft and was unable to control the wind quality. This created high scrap rates, bagging web material in some rolls and material that was too tight in others. It also limited the machine speed and caused costly production bottlenecks.

DRS Shafts Difficult to Maintain

The friction ring style differential shafts needed to be constantly oiled and the oil would drip on the food grade material causing scrap. Excess core dust was being generated and contaminated the friction rings, jamming the cam action of the rings which caused the rings to have difficulty gripping the core and ultimately created more dust and lost control. The rings needed to be disassembled and cleaned on a continuous base. Spare parts for replacement rings and other shaft spare parts from an existing shaft supplier proved costly.

Poor Product Support

The original OEM Incotek went out of business and parts were difficult to find and costly if found. The engineering controls company that re-wrote the machine PLC offered poor support. There was no viable solution being offered from other companies to take ownership of the whole system – machine controls and differential rewind shaft.

The Double E Solution

Double E was able to offer a complete solution for a fraction of the cost required to put in a new machine. To alleviate the tension control issues Double E installed a full tension zone retrofit that included pneumatic brakes with T-One tension controller coupled with load cells on the unwind. A new nip roll was installed to replace the s-wrap to set the constant master speed before slitting. A new EP.42 tension control with a T-One controller was used with a US.3 sensor for the rewind. The T-One DRS automatically controls rewind motor drivers and DRS shaft air pressure to achieve proper torque and rewind overspeed all while managing the desired taper tension. This removed all of the "trial and error" guessing for the operators to build high quality rolls, even at light tensions. Now with the automatic control and implementation of a nip, the machine was running at 1350 FPM and making great rolls. Previously it never exceeded 500 FPM.

Now this machine is a versatile part of the production and is used to schedule more demanding jobs and increasing company's capacity and throughput. Double E engineering measured the machine on site and built a custom bolt-on nip roller. Now material does not slip through nip and the rewind controls are no longer fighting the unwind controls. Re load cells replaced the old dancers. Unwind motor was replaced with CX.250 brake with adjustable torque capacity to control tension on both light materials with small rolls and heavy materials on larger rolls.

DRS-4200 Shafts that are Easy to Maintain

New DRS-4200 shafts only require very minimal lubrication with no more oil dripping from the central shaft. The DRS-4200 rings are manufactured with tighter dimensions and tolerances to keep dust out and cam action working properly. Now with minimal oil and dust contamination, the shaft running time is increased and maintenance time has decreased.

Complete Product Support

With the exception of the main line speed signal and start/stop signals, Double E control system operates completely independent of existing PLC. Full support is now offered from one company. Both Double E and RE are long established companies that offer worldwide support on all product lines, old and new for years to come.

The new completed upgrade to the customer's machine provided a low cost solution to increase productivity by offering a more efficient tension control solution coupled with a cleaner, easier to maintain and more efficient differential rewind shaft. Now the customer is able to run at higher speeds at a longer period of time with no material waste.

With more than 400 customers, often with very specific demands about their products,a manufacturer of corrugated cartons needed a solution for handling narrow rolls (less than 48-inches wide) of Kraft paper. Their roll stand could not move the arms close enough to pick up these narrow rolls. The customer had created an in-house modification to the roll stand. They created a pre-mounted DF-2000 adapter assembly - a piece of steel pipe with flanges at either end. This solution needed frequent repairs due to damage caused to the chuck when mounting and removing the adapter assembly. The weight and bulk of the adapter assembly made it difficult to handle, and the assembly was frequently dropped. There was also a very real risk of a workplace injury with this adapter. The customer approached Double E to engineer a solution.

Double E's solution to the customer's need to work with narrow rolls of Kraft paper more efficiently was a custom 4" DLB-2000 Core Shaft. Double E designed the shaft to fit between the arms of the roll stand. It is also designed with unique journals that work perfectly with the customer's existing 4" DF-2000 chucks.

The valve-side journal is attached to the shaft like a traditional Double E journal. Double E's proprietary fastening system with its close tolerance, deep insertion journals allow for quick and easy removal should the bladder need to be replaced. The non-valve side journal is a two-piece assembly to facilitate inserting the shaft into the core. A 5" outside diameter keyed journal insert can be removed for shaft insertion and extraction. The inside diameter of each journal is designed to fit seamlessly onto Double E's 4" DF-2000 chucks installed on the customer's unwind stands.

Double E had the pleasure of working with maker of holographic flexible material used for packaging DVDs and other products. The customer was using a square journal shafts and safety chucks from a lesser supplier. The square engagement had a loose tolerance fit that allowed the shaft to drop slightly every quarter turn of rotation. While the rotational tapping was irritating, the real problem was the uneven tension and bouncing that often caused wrinkling in the web. A wrinkle early in the rewind process resulted in significant portions of a roll being wasted. Sometimes, the whole roll was unusable. The company's difficulties were compounded by the maker of the shafts and chuck's poor customer service.

Double E's solution to the customer's web tension and bouncing problems began with the Safety Chuck with circular jaw inserts. The safety chuck's circular, spline design minimized the roll bounce, vibration noises, and uneven web tension. Because the spline design is proprietary, Double E also supplied SR-2000 strip shafts.

As it turned out, the bouncing problem was being caused not only by the safety chucks but also by shaft tolerance and strip compression. Double E offered the customer one trial SR-2000 shaft with the new safety chucks. The customer uses a lay-on roller directly on top of the rewind roll. This roller's movement made it possible to see the web bouncing during rewind. The trial run with the SR-2000 focused Double E's efforts toward eliminating the clearance between the OD of the shaft and the ID of the core.

To solve the remaining problem, Double E applied the SRS-2000 self-centering strip shaft. This shaft is machined to a custom OD rather than extruded like the SR-2000. The shaft also combines gripping strips with plastic centering strips. This design minimizes roll bounce due to bladder compression. The SRS-2000 shaft corrected the tension and bouncing issues on the web. In addition, the customer was pleased with Double E's customer service performance and readiness to work with them.

The customer purchased 15 SRS-2000 strip shafts and 7 sets of SM-100 safety chucks. This combination of products works for many flexographic and plastic applications. It is crucial to pay attention to the ID of the core. The SRS-2000 is custom machined and can fit the customer's core more precisely.

Double E often has direct replacements to make upgrading from other manufacturer's chucks simple, but even when a retrofit is more challenging, Double E applies its experience and expertise to solve problems for its customers. As an example, Double E recently worked with a flexible packaging converter that needed to replace safety chucks because parts were no longer available. Since the bearing housings on the existing safety chucks were integrated into the machine frame, the customer was having difficulties finding a direct replacement.

Double E engineers designed new safety chucks to fit the customer's machine by taking measurements from the existing spindles. They planned carefully for a tricky installation then machinists manufactured two pairs of custom modern chucks with sliding faceplates to replace the old ones. Installing the new chucks would be challenging because of their position on the machine, but the Double E engineers took this into consideration. They created special mounts that would allow seamless integration. With a few minor adjustments on-site, the safety chucks fit properly into the machine, and the safety chuck upgrade was complete.

Double E also provided new 6" strip shafts to be used with the safety chucks, and DF-2000 core chucks (on the unwind) to complete the project. Double E was able to extend the life of the customer's dependable turret winder machine and today the product line is running at full capacity. The production manager expressed his appreciation for how dedicated and detailed oriented Double E was throughout the project.

This project demonstrates Double E's ability to help its customers by engineering custom solutions.

Double E had the pleasure of helping one of the world's leading manufacturers of automobile air bags with a safety concern they were having. The safety chucks on the customer's unwind stand are approximately seven feet above the factory floor. When the master roll is loaded or unloaded, workers were climbing up the machine to reach the safety chucks and/or using a mallet to open and close the safety chucks. The machine did not provide a catwalk to facilitate access to the safety chucks, creating an unsafe work environment.

Double E's solution to the customer's factory safety issue was to provide the AP/SM100/P0/IV40 and AP/SM100/ P1/IV40 pneumatic safety chucks. These safety chucks use air pressure to open and close the safety chucks, removing the need for workers to scale the machine each time the unwind roll was changed. To further enhance safety and ease of use, Double E's engineers designed these pneumatic safety chucks to communicate with the machine's automated controller. The safety chucks are button-activated at the machine's control panel. The pneumatic safety chucks use three proximity sensors. Indicator lights inform the operator whether the safety chucks are open or closed. In addition, Double E's engineers designed a "safety switch," so that the unwind stand will not operate when the safety chucks are opened or improperly oriented.

Double E's solution to the customer's plant safety concerns demonstrates the company's ability to improve existing machine designs. Double E's work to integrate the pneumatic safety chucks into the customer's existing automated system provided a direct, elegant solution that enhanced both plant safety and productivity. Double has since provided 29 pairs of these safety chucks to the customer.

A producer of roofing material that uses an offline slitter for roofing paper was concerned with their old OEM knife holders which were producing an inconsistent cut quality due to the holders creating vibration at the cut point from instability. Control of the vertical overlap, cant angle, and side load was crude and led to inconsistent cut quality from roll to roll. This would cause rejected rolls, excessive downtime and unfortunately, lost profit. The original dovetail rail increased the setup time due to the difficulty in positioning the holders and added to the rejected rolls. Safety was also a major concern since the blades were always exposed. The risk of an injury always loomed over the plant manager.

Double E engineers recommended upgrading the holders and rails to the Mario Cotta "Gold" series. The gold holders dual shaft design provides stability at the cut point which improves overall cut quality. The precise and consistent control of the overlap, cant angle, and side load gives the operator confidence that the slit quality and accuracy of every roll is the same. The user friendly setup knobs reduce downtime and allow for increased throughput. Removable blade cartridge makes it safer to change blades and allows operators to reduce downtime by swapping in a new cartridge. The new rack and pinion rail provides a smooth, accurate positioning that adds to the improved finish roll quality and reduced downtime.

The new upgrade to the old slitter provided efficiency, cost savings, and increased product quality. The customer has since expressed how impressive the new slitter machine performs but what the customer was most impressed with is the level of safety that the new Gold holders provide. Since the blade cartridges could be removed before changing out the blade there was reduced concern for any operator accidents. The full protective guards added to the overall safety of the holders.

For more information, please contact Double E Company, the exclusive distributor of Mario Cotta slitting equipment in North America.

A producer of 200Ib specialty paper approached Double E about concerns regarding the instability of their Tidland class III holders at the cut point. At high web speeds of 6,000 fpm the blade would shake due to the narrow dovetail rail and construction of the holder itself. This would cause rejected rolls, which forced the customer to shut down the line often and throw out wasted material. The dovetail rail not only added to the instability but also increased the overall setup time due to the difficulty in positioning the holders. Safety was also a concern, since the blades were always exposed, increasing the risk of a potential injury.

Double E recommended the new Mario Cotta "Platinum" series high performance, heavy duty knife holder with upgraded rack and pinion rail system. This robust holder features a dual shaft design that provides stability at the cut point, improving the cut quality even at high speeds. The precise and consistent control of the overlap, cant angle, and side load gives the operator confidence that the slit quality and accuracy of every roll is the same. The user friendly setup knobs allows the operator to set each knife the same way, which yields consistent results from knife holder to knife holder and shift to shift. Removable blade cartridge makes it safer to change blades and allows operators to reduce downtime by swapping in a new cartridge. The new rack and pinion rail provides a smooth, accurate positioning that adds to the improved finish roll quality and reduced downtime.

The new upgrade provided efficiency, cost savings, and increased product quality. The customer has since expressed how well the slitter machine performs but what the customer was most impressed with is the level of safety that the new Platinum holders provide. Since the blade cartridges could be removed before changing out the blade there was reduced concern for any operator accidents. The full protective guards added to the overall safety of the holders.

One of the largest pressure-sensitive roll label suppliers in the country approached Double E with concerns about the slitting section on one of their production lines. They were not happy with the setup of their current holders and the quality of the cut the slitters were producing. The customer uses a doctor machine for line inspections that utilizes a series of Mario Cotta "Gold" series knife holders. They were so impressed with the ease of use and quality of the holders that they asked Double E to develop a simi¬lar system for their production line machine.

Double E went to work designing a slitting system that would easily bolt onto the existing machine. All twenty of the old holders were replaced with new "Gold" series holders attached to a new support beam. This much more robust support beam features a rack and pinion rail system allowing the operator to adjust the knife position more easily and accurately.

On the anvil side, the customer required a digital readout to position their anvils. Unfortunately, due to the excessive adhesive buildup, they needed to be able to move the digital readout system out of the way to clean the anvils. To alleviate this problem, Double E engineered a digital readout system on a linear rail that is pneumatically actuated so that the machine operator could move the system out of the way during maintenance and cleaning. Installation of the new system went smoothly once all of the components were delivered to the customer. The complete modification of the machine including disassembly of the old parts and fitting the new knife holder system and digital readout system took less than a business day.

Once the knives were adjusted and calibrated, the production line was ready to run at full capacity. The customer has since expressed how pleased they are with the new modifications to their slitting machine. The ease of use along with the added safety has given the customer true piece of mind knowing that their product is at the highest possible quality and their operators are safe during routine maintenance.

The Double E Company has worked closely with many customers over the years regarding solutions to slitting dilemmas. Recently a customer in the tissue industry came to Double E looking to upgrade from the tried and true Mario Cotter PPS model to a newer knife holder. The customer was able to get many years of service from the PPS but dust was starting to build up due to the excessive cant angle on the holders and worn out multi‐groove anvils. Another problem was that the holders were located inside their Fabio Prerini Slitter/Rewinder machine with very limited
access and they needed a holder that provided easier blade changes. Double E introduced the customer to the "Gold" series knife holder by Mario

The production manager agreed to purchase a Gold series holder for a brief trial period. Since the customer was upgrading to a newer Mario Cotta device, the drop‐in replacement was effortless. The production manager was intrigued by the knife holder's mounting flexibility and once the production line started using the device, he soon realized the benefits of the error‐free cant angle adjustment and the blade guard safety feature. The line operators found it easier than ever before to replace blades…because the simple cartridge system allows them to pull one out and replace it without tools.

The production manager was so pleased with the "Gold" series knife holder that he immediately outfitted his entire production line with "Gold" series knife holders and multi‐groove anvils. These Mario Cotta holders save time, yield unparalleled cut quality, and alleviate the dust issue. He also has the peace of mind of knowing that parts availability and product support are never a problem with Mario Cotta.

For more information, please contact Double E Company, the exclusive distributor of Mario Cotta slitting equipment in North America.

Double E recently worked with a customer who was having inefficiency problems with one of their slitting sections. The company is a producer of technical, filter, and specialty papers that runs a variety of materials and setups for a wide range of customers. Often, they will run one setup for each master roll, requiring several knife setups per shift. The facility runs two shifts during the day; each with two operators. Setup time often takes half an hour as the tolerances required as tight as +/- 0.015". Unfortunately, this setup would be done by the human eye and a set of calipers. It would require the operators to make setup changes until their computer system accepted a sample slit that was in tolerance. Running up to seventeen master rolls per shift proved that there was a significant amount of wasted time, and ultimately, wasted money each day.

Double E assisted with the company's inefficiency problem by providing a new fully automatic Mario Cotta "Expando" slitting system. This system consisted of a custom "Expando" slitting station that would be retrofitted to the customer's existing Menzel machine. The station would be installed with twenty Mario Cotta "Gold" series holders connected to a new computerized control panel.

The setup proved tricky since the web path needed to be changed to tangential with individual anvils which is required for any automatic system. To begin the installation, the old knife rail and anvil shaft had to be removed. Then a section of the back panel of the drive side cabinet and tending side cabinet had to be cutout in order for the new slitting station to be fit into position. Once the station was securely mounted, the chain drive system had to be rerouted to accommodate the new position of the knife shaft. Next, two new electro-pneumatic control boxes were mounted on brackets over the drive cabinet and the hoses were fed into the machine through the cutout in the cabinet's back panel. Once the system was connected to the control panel, and the holders and anvils were installed, the system could then be fully calibrated.

The Double E / Mario Cotta fully automatic positioning solution allowed the customer to reduce setup time to less than three minutes and allowed the customer to reassign one operator from each shift to other responsibilities in the plant. The customer will realize the return on their investment in just a few months since they can increase the throughput of the machine each day and also reduce the overhead of their employees on that machine. Additionally, they no longer have to rely on the ability of an operator to set the knife holders to a tolerance of +/-0.015" as the system will do that for them. The customer only has to enter the number of slits and slit width into the computer and the system will automatically position the knife holder and anvil relative to each other. The system also allows the customer to realize additional time and cost savings by using the "Gold" knife holder and "Expando" style anvils.

The customer's initial reaction to the system was pure amazement. Once the operators were trained on the new software, the customer could see firsthand how this new system would save them time and money. Double E is now discussing with the customer about a similar system, with a smaller number of knife holders, for their adjacent slitter.

Recently the Double E Company worked with a customer that converts wrapping paper with various thicknesses. The production manager was having cut quality problems with the company's old OEM knife holders and parts availability problems with replacement holders that the company had purchased not too long ago. He was frustrated with being forced to upgrade to new holders, but since he was being forced to do it anyway, he decided to test a better solution. Double E introduced the customer to the "Gold" series knife holder by Mario Cotta.

The production manager agreed to purchase one holder for a 30-day test. It was easy to mount the new holder on the slitting machine with a simple bolt on adapter bracket, and the line was up and running in no time. He was intrigued by the knife holder's mounting flexibility and once the production line started using the device, he soon realized the benefits of the error-free cant angle adjustment and the blade guard safety feature. None of his previous holders had these types of standard features. Operators also found it easier than ever before to replace blades...because the simple cartridge system allows them to pull one out and replace it without tools.

The customer was so pleased with the "Gold" series knife holder that he immediately ordered three more. Now the production manager has absolute confidence in his production line. The Mario Cotta holders save time, yield unparalleled cut quality, and provide a higher level of safety for his personnel. He also has the peace-of-mind of knowing that parts availability and product support are never a problem with Mario Cotta.

For more information, please contact Double E Company, the exclusive distributor of Mario Cotta slitting equipment in North America.

Several years ago, a major producer of printed paper bags was struggling with poor edge quality. The edge on rolls being provided by the company’s supplier wasn’t consistent enough to print close to it without trimming, and the rudimentary trim system that came with the machine delivered poor cut quality. It was a simple blade rotating at the speed of the web without enough control or stability. Operators couldn’t get consistent results when print needed to bleed to the edge of the paper. When they tried to print close to the edge, they would end up with messy ink on their rollers and excessive material waste due to unacceptable finished bags.

Precise edge trimming was the key to ensuring that words and images would not be cut off or folded over when the paper was trimmed, glued, and formed into paper bags. The company needed a solution that would guarantee dependable edge quality for all of the paper grades that they run (30 – 100 point).

Mario Cotta’s “Kobe” edge trim system was the solution. The Kobe is specifically designed for trimming edges of continuously moving webs with a motor-driven bottom knife assembly. The system features pneumatic upper knife holders for shear cut precision. The Maintenance Manager at the plant explained that they invested in the first system as a test. The test went so well that they have since purchased ten systems, and plan to buy many more. “Ultimately”, he explained, “every line in the plant will run with the same system.”

In addition to solving the edge quality problem, the Kobe systems have also allowed the company to increase their line speeds and improve throughput. The blades on the knife holders last a long time and maintenance on the system is rare. The Maintenance Manager at this particular plant chose the manual positioning model with digitally-assisted rack and pinion postioning, but motorized digital positioning and fully automatic positioning systems are also available.

For more information, please contact Double E Company, the exclusive distributor of Mario Cotta slitting equipment in North America.

A producer of laminates and performance films used for tents, banners, movie screens and pool liners approached Double E with a problem they were having. The rubber/vinyl material they were running had various thicknesses at a web width of 84" with a minimum slit of 2" and a maximum speed of 75fpm. The customer had a problem with their slitting section which was setup with razor cut blades. When running thicker material through the line at higher speeds, the blades would wear down too quickly which resulted in continuous machine shutdown. This excessive downtime lead to lost profit and the customer needed a solution to significantly reduce this problem. The customer turned to Double E for a solution.

Double E engineered a new retrofit slitting section upgrading the line to shear system using the Mario Cotta "Gold" seriesknife holders and "Expandette" removable bottom knives. This tried and true combination provided the customer with superior slitting quality and efficiency. The "Gold" holder provided longer blade life, superior cut quality, quick blade changes, and easy calibration once the blades have been resharpened. The "Expandette" removable bottom knives provided additional reduced maintenance time with rings that are easily replaced without removing the anvil from the shaft. These holders and bottom knives were mounted on a custom retrofit stand that easily bolted to the machines existing frame providing a seamless upgrade.

The customer has since expressed how pleased they are with the new slitting section since the solution not only provided better efficiency and less downtime but also provided flexibility in mounting razor cartridges if they needed to run thinner material. The customer also expressed that this was the easiest retrofit he has ever done. The stand bolted right into the existing holes and didn't require any additional modifications. Now the customer is able to run the line longer with superior cut quality and minimum maintenance downtime.

Double E recently worked with a converter of packaging and specialty printing material that runs a variety of web widths and materials with a range of high and low tensions. The company had a situation where they needed more efficiency and flexibility with their old Cameron slitter rewinder. The machine used a hydraulic system that proved difficult to maintain since it needed regular servicing and became expensive to operate due to the power to the motor and regular fluid changes. The hydraulic braking system was big and sized for the largest possible roll; every job was setup at the maximum brake setup and would often lose control of the tension. Another problem involved the shaft, which had to be coupled to the braking system every time it needed to be loaded and unloaded. The shaft was then crudely clamped down and if the operator neglected to clamp down the shaft then there was possibility of the roll slipping causing damage to the machine, material and possibly injuring the operator. The customer also had problems with their hydraulic web guiding system which could only edge guide. A better system was needed to slit material reference to a printed line instead of the edge to minimize rejects resulting from material being cut too far or close to the printed line.

To solve these issues, Double E engineered an unwind stand that would replace the unwinding section of the customer's Cameron machine. This stand featured a lightweight DG-2000 aluminum bladder shaft that would grip the core evenly rather than using cone chucks to hold the material which can rip out the core and loosen the roll during winding. The shaft was held in place by flange mounted safety chucks that provided a safe way to lock the shaft into the winder. To provide the needed tension a Re CX.250 pneumatic brake was installed. This brake would allow the customer to turn on and off the calipers of the brake depending on the type of material being wound giving them flexibility and control. The tension control system was then upgraded to an automatic closed loop system using load cells and a new line guiding system was introduced. This would allow the customer to better regulate the winding and eliminate any issues with excess slack or stretching of the material.

The new upgrade to the customer's Cameron winder provided the customer with an efficient system that could make corrections in real time thanks to the upgraded automatic tension control and line guiding system. Safety was also achieved with Double E's smaller lightweight shafts coupled to safety chucks that lock the shafts into place. This new system would also provide cost savings with less material waste. Since the old hydraulic system was eliminated, there would also be additional cost savings due to the elimination of maintenance costs. 

The customer was very pleased with this new upgrade to their machine but what they were especially pleased with was the quick turn around on this project. Since Double E had a similar "CL" (closed loop) model already available, with some slight modifications the stand was able to be delivered in only two weeks time. This allowed the customer to fulfill the obligations with their customers.

Recently a producer of plastic netting for the construction and packaging industry approached Double E regarding their unwind system. The customer uses unwind stations to feed film into their knitting machines. These unwind stations were found to be very inefficient due to the time it took to load and unload the rolls. The system also had tension control problems causing the web to break unexpectedly. This resulted in up to four to five hours of down time to re-configure the knitting machine. The roll stand had a manual braking system but was not setup to detect a signal from the machine which made it difficult to make adjustments to the tension while the web was running. Safety was also a growing concern since the shaft laid in shallow nylon groove rather than being held securely to the stand.

For this application, Double E engineered a simple and efficient system that would easily bolt onto custom stands built by the customer. This system consisted of a DG-2000 aluminum bladder shaft, a Re CX-250 pneumatic brake, and two pedestal mounted safety chucks with side-lay adjustment. The lightweight aluminum shaft allowed the customer to quickly and easily change out rolls while the safety chucks held those rolls in place. The pneumatic brake worked seamlessly in regulating tension by taking a signal from the machine and automatically applying just the right amount of resistance to keep the web at a constant speed.

Double E provided this basic system to four of the customers knitting machines and the customer has since expressed satisfaction with the performance of the new unwind sections. Productivity has increased due to the more efficient roll changes and profit loss has decreased due the elimination of web breaks. Safety is no longer a concern since the new side-lay safety chucks hold the shafts securely in place. 

Double E recently helped one of the world's largest commercial printing companies meet a new slitting requirement for one of its clients. The printer uses a Xeikon digital web press for special projects that run an 80 Ib., 20" wide web material at a speed of 40 feet per minute. The press did not have any slitting capabilities, but the new project required the material to be slit into two 9.5" sections. This production technique would be more efficient and cost effective, but they were having problems making the center cut. Double E recommended a shear center cut system to solve the problem.

Double E engineered a custom stand-alone center cut station that would fit between the printing and rewind sections of the Xeikon digital press. Since there was a very small space to work in (only 20" in length), this proved to be quite a challenge. However, Double E was able to create a completely customized stand that was compact enough to fit between the machine's two sections, while also matcing the web's height so that there would be no need to make adjustments to the Xeikon digital press. This station featured a Mario Cotta "Tiny" shear cut pneumatic holder to provide a high quality cut, with the added benefit of a long blade life. Integrating the new slitting station was not difficult for the customer – an air line for the pneumatic holder, power for the Siemens motor, and a speed reference signal that would regulate the speed were the only connectinos needed.

The customer is pleased with the results of the slitting station. The stand fit perfectly within their Xeikon machine and the basic plug-and-play delivery minimized down time. Once all of power, air, and signal lines were connected, the slitter worked with great efficiency to provide a high quality cut to the web material. When the slitter wasn't needed, the web would simply run smoothly through the station without disrupting the line speed and tension. The customer also ordered a duplicate slitting station for the same type of machine at one of their other facilities.

Double E has always taken pride in applying its experience and expertise to help customer's upgrade their existing converting machine to perform more efficiently and provide a higher level of safety for their operators. As an example, Double E recently worked with a leading supplier of sustainable plastic sheets, compounding and packaging solutions. At one of their larger manufacturing facilities for custom sheets and roll stocks, Double E helped the customer deal with tension control issues on a couple of their production lines.

The first line had a double unwind with a steel bar using two clamp cones stuck into tired looking safety chucks. This line also had a tension system that consisted of a crude and unsafe clamp tightened on a drum. Since there was no true tension control on the material, it had a tendency to stretch and wrinkle going into the plastic calendaring rolls. The second line had a similar setup with clamp roller bearings and a solid steel shaft which also lacked tension control. This line also proved very inefficient in that it only had one unwind.

To alleviate the issues on the first line, Double E engineered a double roll stand that would mount up to the frame on the customer's machine. This stand consisted of two DG-2000 aluminum bladder shafts held by four safety chucks and regulated by two Re pneumatic CX.250 brakes. Close loop tension controls with load cell frames were used to regulate tension. A similar setup was engineered for the second line. However, instead of engineering a complete double roll stand, Double E used the customer's existing unwind upgrading the safety chucks, shafts and brakes and then mounting a second bracket with a chuck, shaft and brake combination in order to successfully convert to a more efficient double unwind. A special bracket was then built to hold a load cell frame to allow for tension control. This would allow the customer to perform quick roll changes utilizing the double unwind configuration and provide tension control for both production lines.

By building a whole new double unwind stand on the first line and upgrading the second line to a similar configuration by utilizing what the customer already had, Double E was able to alleviate the tension issues that the customer experienced. Currently Double E is engineering similar solutions for their remaining production lines. This project should prove to be an incredible return on the customer's investment due to the increase in productivity, product quality and safety for the machine operators. 

Double E worked with a producer of laminated film used in the communications industry who had a situation where they needed a more efficient method for manufacturing a laminated film that consisted of five-layers. Originally, a three-layered material was being manufactured that only required three unwind stands feeding material into a nip section. However, the five-layered material was proving problematic since the entire production line needed to come to a complete stand still in order to move the material back onto two of the unwind stands so that the additional two layers could be added. This proved to be a very time consuming and costly process.

To solve this problem, Double E engineered a triple unwind roll stand that would replace one of the customer's single unwind stands on the bottom level of the production line. Double E was able to seamlessly incorporate the new stand using a single control panel with three Re EP.25 T-Onecontrollers. The stand incorporated six safety chucks, threeDG-2000 aluminum bladder shafts, three Re Combiflex pneumatic brakes, and six Re TC load cells. This complete system would allow the material to run continuously without the need to shut down the machine, bring the material back into position and run it through a second time.

Double E aluminum rollers were added just outside the unwind stand to allow for an even feed while going through the nip section of the production line. These rollers were placed on brackets that would bolt onto the customer's machine. Now the customer has the ability to run the machine at an even pace without the hassle of shutting down production to re-configure the machine. This will give the customer the ability to produce a consistent, high quality product but more importantly, this will provide them with a tremendous return on their investment. 

Recently the Double E Company worked with a producer of large-format digital graphics who specializes in large scale banners and billboards. The company had a situation where they needed a way to manufacture a welded pocket seam in the film material before it went to print. They were trying to unwind a 5" film strip, fold it in half and weld the edges together. The process they were using proved unsuccessful so they asked Double E to engineer a small tension controlled unwind station that could be easily mounted to the production line.

Double E's solution featured a narrow web device consisting of an SR-2000 strip chuck mounted on a safety chuck body and regulated with a Re Eleflex electromagnetic powder brake. This narrow web station combined with the Re CF.85 load cell, tension roller and integrated tension control system with a T.1 controller provided the solution for regulating the tension during the unwind process. The customer was now able to provide a consistent method for welding the pocket seam.

The success of the initial narrow web station prompted the customer to order four more units for each of the production lines.

For more information about the CBA-1000 Narrow Web Unwind / Rewind Stations, please contact the Double E Company.

Recently the Double E Company worked with a customer that converts products for the transportation industry. The customer had a laser cutting machine that pulls material off of an unwind roll using mechanical grippers and stepper motors. Unfortunately, a new material being used during the converting process was very stiff with a high tension. The laser cutting machine was found not strong enough to pull the material off of the roll which slowed production down.

Double E solved the customer's dilemma by providing a nip feed station that synchronized with the start/stop signal of the laser cutter. This allowed them to automatically feed the material off of the unwind stand and onto the table of the laser cutter. Now production could continue at an even pace with no material problems.

For more information about nip/roll stations, please contact Double E Company.

One of the largest producers of register tape in the country needed to increase production by adding an additional printing press line. However, they did not want to use the same web guide system as their current lines since they are not satisfied with the accuracy and performance. The correction and response time was slow which caused wasted print and lost profit.

Double E's solution was to offer a Re series WG pivot frame web guiding system with an RK31 remote web guide controller on a customized frame to match the customer's other lines. This system utilizes two parallel rolls positioned where maximum precision is required, with the sensor placed just after the output roll. This puts the least amount of stress on the web material and provides the most precise guiding.

The customer's new Re web guiding system now provides faster and more accurate corrections than the other systems on their other production lines. This more efficient line produces little to no waste which increases the customer's profit. The customer especially liked the ease of use and quick setup. Double E has since quoted a replacement for their other production lines to increase their capacity and efficiency.

Recently one of the largest bag manufacturers in the country was struggling with web tension control in the unwind section of the converting process. The paper material was spooling and tugging at the line, making it necessary to run at slow speeds and with constant manual adjustments. A combination of Double E / Re web accessories, including an integrated tension control system solved the problem.


Double E utilized the customer's existing unwind stand by engineering a shaft, chuck and brake combination that would bolt directly to the stand. The new unwind components included a three-inch expanding strip shaft, two safety chucks and a single Re CX.200 pneumatic brake. This combination made it possible for the customer to unwind multiple roll widths while ensuring roll security and easy loading. To measure and control the tension, Double E provided Re CF.85 load cells and a Re EP.25 control system with a T-One tension controller. Now the customer has the ability to adjust the set-point and provide a smooth even tension throughout the unwind.


The upgrade also used a Re web guide shifting actuator AT guide to facilitate lateral movement of the stand. By having this flexibility, the customer eliminated a secondary problem of potential misalignment of the laminated layers.


After the installation, a Double E field engineer met with the machine operator to provide training for the T-One controller. The customer was so pleased with the process improvement results on this part of the machine that a secondary project is now underway. Double E will provide a solution with an open loop control and brake for the plastic film unwind portion of the same machine. Currently the customer is using a system of weights being hung from a pulley attached to the shaft. This primitive, completely manual system is difficult to maintain and imprecise. Double E's replacement will include an additional shaft, chuck and brake combination that will link into the existing tension controller. The entire line will be easy to control from one location.

Last year the Double E Company worked with a customer that produces a variety of flexible packaging materials employed in the food, medical, industrial and chemical industries. This customer runs six different printing lines in its 70,000 square foot facility two of which are 8-color central impression type flexographic presses. These presses produce high quality process work at very high speeds. The customer was in dire need of a reliable, simple way to check print quality during the run, since the speed of the line makes checking manually virtually impossible.


Both of these flexographic presses had previously installed web vision systems. One used a five-year-old camera system manufactured by a company that has since gone out of business. Obtaining parts and support for this product was out of the question. The other flexographic press used a different web vision system that was complicated to run and required frequent, expensive repairs. The customer needed a simple, reliable web inspection system that would enable them to check print quality during the run.


Double E's solution to the customer's need for a simple, reliable web inspection system was the Re MH100 Web Vision System. The MH100 is particularly adapted for flexographic and rotogravure printing machines utilizing a CMOS sensor to obtain unmatched color accuracy and image quality. The easy split screen function allows the operators to make quick comparisons with excellent image quality. The automatic scanning also gives the operators the ability to regulate between split vertical, split horizontal, split vertical and horizontal or full screen. This gives the customer the ability to print at high speed and make adjustments quickly which reduces costly material waste.

Today this producer of flexible packaging materials is running at full capacity with minimal down time thanks in part to the Re MH100 Web Vision Systems. Since these systems were installed, both lines have been able to produce stunning products at full speed with very little material waste.


For more information about upgrading or installing high quality web inspection systems like the Re line of Web Vision Systems, please contact Double E Company, the exclusive distributor of Re products in North America.