Upgrade & Retrofit Solutions

TITAN Slitter Rewinders

Improving quality & productivity

Atlas Converting Equipment Ltd. has beenmanufacturing slitter rewinders since 1976and Titan slitter rewinders were firstintroduced in 1964.

Consequently, in almost 50 years more than1,000 Atlas and 2,500 Titan slitter rewinders havebeen installed in over 70 countries worldwide.

Many are still in operation but slitting &rewinding technology has advanced dramaticallyover the years, leaving the older machines to bemuch less productive. Not to mention how muchmore sophisticated the range of materials hasbecome for slitting, especially for flexiblepackaging.

“We are really pleased with the improvedperformance of the Titan SR6 slitter* since theupgrade of the rewind shafts. There is muchless maintenance to perform on the machinewhich means less time lost with the slitter‘offline’ - and less shaft cleaning which makesthe slitting process more hygienic for materialsfor the food industry.

Set-up of the rewind reels is also much easierand quicker now than it was before theupgrade.”

Norman Baldwin, Maintenance Manager Interflex Group, Dalkeith, Scotland *installed 1995 / upgraded 2012

Providing the solution

Atlas is pleased to provide its customers with adedicated service for upgrading the specificationof older slitter rewinders to help increaseproductivity, reduce waste and improve thequality of the finished reels processed. All ofwhich should help to improve the profitability ofconverters’ business operations.

Improved web tension control, replacement ofobsolete components and retro-fitting the latestcomputer hardware & software systems are justsome examples of how Atlas & Titan can supportthe future business of its customers.

Other examples of cost-effective upgrades andretrofit solutions for Titan slitter rewinders are:-

• Control desk upgrades

• Differential Quick Shafts

• Laser core positioning systems

• Slitting & knife systems

• Slit reel unloading systems

• Rewind shaft unloading systems

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Control Desk Upgrades

Product dependent settings can bestored in PDF files, allowing quickchange-over times between differentjobs.

The system gives precise control oftension and contact pressure, providingbetter and more repeatable rewindquality.

The control desk includes severaloptions including AC or DC drives anddata export for production systems viaEthernet.

Other options are also availableincluding an additional control panel forthe unwind, for enhanced operatorcontrol.

AC drive technology is available as anoption, replacing web drive motorswhich help to reduce maintenance.

The desk has a user-friendly touchscreen for all machine controlparameters with hard wired stop/startcontrols.

Titan SR5 control desk - after

For the Titan SR6 slitter, the existing control deskcan be re-used

Control screen

• Obsolescence• Reel quality problems• High maintenance costs• Low production from manual operation

• Complete pneumatic SR6 panel replacement• Digital pneumatic layon control• Digital pneumatic rewind control• Unloader

The effective solution for resolving:

Associated upgrades

Features

• Prolongs operating life of machine• Replaces obsolete control system• Easy maintenance• Simple operation

Benefits

• Recipe & product data file system • Improved winding control • Consistent winding • Reduced maintenance • Improved diagnostics

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Titan SR5 control desk - before

The control desk upgrade for theTitan SR Series slitter rewindersreplaces obsolete units with thelatest technology.

As an option, the complete desk isreplaced with the latest digital PLChardware and software for muchimproved web control.

Finished rewind packages using Quick Shafts

Laser core positioning is a manualsystem which is set only once bythe operator for a specificproduction run.

The lasers are mounted above therewind shaft.

The laser projects a line on to therewind shaft at the point where thecores should be placed.

The laser pointer helps the operator toplace the cores on the rewind shaftsquickly, accurately and consistently.

The accuracy of the positioned coreseliminates the need to adjust the coresduring the run.

Laser line projected onto edge of core

Quick Shafts can be fitted toalmost all Titan and someAtlas slitter rewinders.

The ball lock elements areavailable in various widths from20 - 50mm wide to accomodatenarrower slit widths.

Differential Quick Shafts

Lasers improve roll alignment04 www.atlasconverting.com/upgrades

• Inconsistent core positioning• Machine downtime for core re-positioning• Waste due to re-starts

The effective solution for resolving:

Associated upgrades

Features

Benefits

• Reduced downtime• Improved roll alignment• Lower maintenance• Consistently higher quality rewind reels

• Differential Quick Shafts (essential)• Semi-automatic rewind unloading system• Unloader

• Laser line of less than 1mm• Minimum slit width 40mm• Simple push button operation• Laser on for pre-set time• Safe Class 2 laser to EN 60825-1

• Slow set-up times• Reel quality problems• High maintenance costs

The effective solution for resolving:

Associated upgrades

Features

Benefits

• Even tension control across shaft• Quicker & easier job set-ups• Increased productivity• Reduced core dust

• Laser core alignment• Unloading systems• Digital air pressure controller (E/P) upgrade

• Fast product removal and core loading• Only 15 mins per week maintenance• Reduced core distortion

Quick Shafts work on the principle ofdifferential winding. The torque toobtain tension is transferred usingradial pressure, which ensuresconsistent tension across the web.

The standard diameters are 76 or152mm (3ins & 6ins) and can beavailable in 70, 100 & 170mm as anoption.

Roll-out systems can be fitted as anoption to enable quick changeover toair shafts for lock core winding,enabling full width rewinding.

Differential Quick Shafts require no set-up time for varying slit widths, whichprovides a huge benefit in productivity.

Laser Core Alignment

Versatile knife holders can carry razor,rotary razor or shear blades

Narrow width shear slitting system

The complete range of Titan slitterrewinders can be adapted to runwith razor slitting, rotary razor,shear slitting and center trimsystems.

The correct type of knife for thematerial is very important to maintainthe slitting quality. Knives are availablein various widths which enables narrowwidth slitting.

Slitting & Knife Systems

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• Raised edges • Poor quality slitting• Knife damage

The effective solution for resolving:

Associated upgrades

Features

Benefits

• Improved slitting quality • Improved knife life

• Quick Shafts • Laser core alignment

• Correct blade for application • Narrow slit patterns • Adaptable holders

Razor slitting

The razor units can be stand-alonerazor bar mounted or in the dove tailmounted multi-knife holder. The razorknife is the easiest and fastest to set upof all the knife systems and is suitablefor most flexible materials in variousgrades.

Rotary razor slitting

Rotary razor blades are circular razorblades which rotate in grooves with thesubstrate being processed. The blade ismounted on a free running bearing.This allows the blade to cool during theslitting operation and reduces thedamage to the material, particularly tothinner, more delicate materials.

Shear slitting

The shear slitting system uses male andfemale knives, making a scissor actionfor high quality slitting. The maleknives are available in various formatsto fit on to older machines. Third partyknives are also available, such as Dienesor Tidland. Male knife bars can also befitted as the simplest and lowest costoption.

Female knives are also available inseveral formats Eg. Single or multi-width knives in various widths. Multi-knives enable quicker set-up timeswhich helps to improve productivity.

Centre trim

Centre trim knives are an option whichcan trim out the control lane on printedmaterial. These knives are normallyshear knives and are used in auto-positioning systems. There are alsooptions available for manual kniveswhich use a fixed width system.

Grooved spacers enable quick set-up times with razor blades

Various width female shear knives provideflexibility for variable width slitting

With today’s increasing legislationon health and safety, the Titan SRrange of slit reel handling sytemshas been designed to reduce physicalstrain on machine operators.

The design is particularly suited to foodpackaging applications where machinesare working in a clean and hygienicenvironment.

Reels can be unloaded while themachine is running, increasingproductivity.

The unloading boom can be installedand commissioned in one day(depending on options) and includesalignment to the slitter, interlocks andfull operator and maintenance training.

The maximum weight per shaft is 500 kgfor standard units. However, otheroptions are available.

Titan has developed a semi-automaticreel handling system which integratesthe unloading of the slit reels to varioustypes of conveyors.

Slit reels unloaded to boom

Boom in unloading position

Reel Handling Systems

• Manual unloading of slit reels• Low productivity• Repetitive strain injury (RSI)• Handling heavy reels

• Unloading systems• Differential winding

The effective solution for resolving:

Associated upgrades

Features

• Unloading to boom• Unloading to conveyor (option)• Electric or pneumatic (options)• Semi-automated (option)

Benefits

• Increased productivity• Reduced operator fatigue• Improved roll quality• Reduced package handling• Decreased stop time

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Unloading booms reduce rewind reel handling

The unloading booms are fully integratedinto the recipient machine to ensure asafe working environment for theoperator.

The controls for the unloadingbooms are mounted in a position toenable ease of operation with anergonomic design.

This system dramatically reduces theintervention of the machine operator.

The rewind shaft unloading systemis a retrofit product for the Titan SRrange. The system pushes finishedrewind packages off the rewindshafts to a trolley or unloadingbooms.

This reduces the risk of repetitive straininjuries. It also reduces damage to thefinished rolls due to improved handling,delivering better quality rewind reels.

Operation is easy with a user-friendlytwo-handed control system for safety.The control systems are integral to therewind shaft unloading system for easeof installation and maintenance.

The system is used in conjunction withan unloading trolley or a semi-automated unloading boom.

Laser core alignment can beincorporated to allow easy re-coring ofrewind shafts, reducing damage tocores and friction elements due to ‘coreknocking’ during set-up.

The rewind shaft unloading system hasa low maintenance AC drive usingstate-of-the-art inverters to control theAC motor.

For the Titan SR5, SR6 and SR7 therewind unloader is mounted above therewind section with a single paddle tostrip the reels from the shafts. For theTitan SR8, the unloader is mountedbelow the rewind shafts.

All rewind shaft unloading systems areintegrated into the machine controls toreduce the wear on the differentialwinding system.The unloading cycle takes between 10-20 secs

Laser core positioning system

Semi-automatic Rewind Shaft Unloading

• Production losses from operator fatigue• Operator complaints regarding package weight• Repetitive strain injury (RSI)• Handling heavy reels

• Laser core positioning• Unloading trolley or boom• SR7 style door for SR5 & SR6• Differential Quick Shafts (essential)

The effective solution for resolving:

Associated upgrades

Features

• Suitable for 70 - 152mm rewind shafts• Local operator controls• Unload cycle time 10 - 20 secs, plus re-coring• Automatic core unlocking (Quick Shaft)

Benefits

• Cost-efficient unloading• Reduced risk of repetitive strain injury (RSI)• Increased productivity

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A new rewind unloading system fitted to a TitanSR5 slitter rewinder increases production

EuropeAtlas Converting Equipment Ltd.8 Wolseley Road, Woburn Road Industrial EstateKempstonBedford MK42 7XT United Kingdom

T: +44 1234 852553F: +44 1234 851151upgrades@atlasconverting.comsales.titan@atlasconverting.com

AmericaAtlas Converting North America, Inc.9801-F Southern Pine BoulevardCharlotte, NC 28273United States of America

T: +1 704 587 2450F: +1 704 587 2451upgrades@atlasconverting.comsales.usa@atlasconverting.com

AsiaA.C.E. (Shanghai) Trading Co. Ltd.6P, New Shanghai International Tower360 South Pudong RoadShanghai 200120 China

T: +86 21 6886 2501F: +86 21 6886 2502upgrades@atlasconverting.comsales.titan@atlasconverting.com

Atlas Converting Equipment (India) Pvt. Ltd.Plant No.13, Extension Office BuildingEastern Express HighwayPirojsha Nagar, Vikhroli (East)Mumbai 400 079 India

T: +91 992 081 9791F: +91 222 623 3009upgrades@atlasconverting.comsales.titan@atlasconverting.com

www.atlasconverting.com/upgrades

Upgrades and Retrofits - Titan

Data is non binding. Contents are subject to modification without notice. © Atlas Converting Equipments Ltd. 2013

Titan Controls AC Drives Laser Core Rewind Shaft Reel Slitting & Differential Model Alignment Unloading Handling Knife Systems Rewind Shafts

System 70 - 170 mm

SR3 X

SR4

SR5

SR6

SR7 Incl.

SR8 Incl.

SR9 Incl. Incl.

ER610 Incl.

SR1 1964 SR2 1965 SR3 1972 SR4 1978 SR5 1980

SR6 1990 SR7 2000 SR8 2004 SR9 2011 ER610 2008