Converting
Encyclopedia
Converting companies are companies that specialize in combining raw materials such as polyester
s, adhesives, silicone
, tapes, foams, plastics, felts, rubbers, liners and metals, as well as other materials, to create new products.
Materials such as paper
, plastic film, foil and cloth often are produced in long, continuous sheets that are rolled up for more-convenient handling and transportation. These rolls of material vary significantly in size and weight — ranging from 2 to 200 in. wide and weighing as much as several tons. The converting industry takes these continuous rolls of thin, flat materials — known as webs — threads them though processing machines (such as printing presses, laminating, coating and slitting machines) and converts or changes the web of material into an intermediate form or final product. For example, a converter’s equipment might take a web of plastic film, cut it into lengths, and fuse their edges, thus converting it into plastic bags. This activity is known as web processing.
Web alignment is an important part of a converting operation as a moving web of material has a tendency to track off course and wander out of alignment during converting processes. To avoid these problems, engineers have developed a variety of automatic web-guiding systems that assure production accuracy and reduce waste. Web-guiding systems typically are positioned just before a critical stage on a converting machine (for example, just before a print station on a printing press).
Each type of web guiding system
uses a sensor to monitor the web position for lateral tracking, and each has an actuator to shift the running web mechanically back on course whenever the sensor detects movement away from the set path. Actuators may be pneumatic or hydraulic cylinders, or some kind of electromechanical device. Because the web may be fragile — particularly at its edge — non-contact sensors are used. These sensors may be pneumatic
, photoelectric, ultrasonic, or infrared. The system’s controls must put the output signals from the sensors in to a form that can drive the actuator. Many controls today are electronic, typically using an amplifier to convert signals from the sensor, then commanding a special servo motor incorporating a lead or ball screw for guiding actuation.
Coast Controls, Inc., manufactures the world’s only proportional, all-air pneumatic web guiding system.
Polyester
Polyester is a category of polymers which contain the ester functional group in their main chain. Although there are many polyesters, the term "polyester" as a specific material most commonly refers to polyethylene terephthalate...
s, adhesives, silicone
Silicone
Silicones are inert, synthetic compounds with a variety of forms and uses. Typically heat-resistant and rubber-like, they are used in sealants, adhesives, lubricants, medical applications , cookware, and insulation....
, tapes, foams, plastics, felts, rubbers, liners and metals, as well as other materials, to create new products.
Materials such as paper
Paper
Paper is a thin material mainly used for writing upon, printing upon, drawing or for packaging. It is produced by pressing together moist fibers, typically cellulose pulp derived from wood, rags or grasses, and drying them into flexible sheets....
, plastic film, foil and cloth often are produced in long, continuous sheets that are rolled up for more-convenient handling and transportation. These rolls of material vary significantly in size and weight — ranging from 2 to 200 in. wide and weighing as much as several tons. The converting industry takes these continuous rolls of thin, flat materials — known as webs — threads them though processing machines (such as printing presses, laminating, coating and slitting machines) and converts or changes the web of material into an intermediate form or final product. For example, a converter’s equipment might take a web of plastic film, cut it into lengths, and fuse their edges, thus converting it into plastic bags. This activity is known as web processing.
Web alignment is an important part of a converting operation as a moving web of material has a tendency to track off course and wander out of alignment during converting processes. To avoid these problems, engineers have developed a variety of automatic web-guiding systems that assure production accuracy and reduce waste. Web-guiding systems typically are positioned just before a critical stage on a converting machine (for example, just before a print station on a printing press).
Each type of web guiding system
Web-guiding systems
Web-guiding systems are used in the converting industry to position flat materials, known as webs, before processing. They are typically positioned just before a critical stage on a converting machine...
uses a sensor to monitor the web position for lateral tracking, and each has an actuator to shift the running web mechanically back on course whenever the sensor detects movement away from the set path. Actuators may be pneumatic or hydraulic cylinders, or some kind of electromechanical device. Because the web may be fragile — particularly at its edge — non-contact sensors are used. These sensors may be pneumatic
Pneumatic web guides
A Web is a term used in the Converting Industry that refers to continuous rolls of thin, flat materials like paper, film and plastic. Web guiding systems use a sensor to monitor the position of a web as it enters a production process for lateral tracking...
, photoelectric, ultrasonic, or infrared. The system’s controls must put the output signals from the sensors in to a form that can drive the actuator. Many controls today are electronic, typically using an amplifier to convert signals from the sensor, then commanding a special servo motor incorporating a lead or ball screw for guiding actuation.
Coast Controls, Inc., manufactures the world’s only proportional, all-air pneumatic web guiding system.
Services
Many converters specialize in- adhesive coating to make Labels and TapeAdhesive tapeAdhesive tape is one of many varieties of backing materials coated with an adhesive. Several types of adhesives can be used.-Types:Pressure sensitive tape...
- silicone coating to make a release linerRelease linerA Release liner is a paper or plastic based carrier web material, which is coated on one or two sides with a release agent, which provides a release effect against any type of a sticky material such as an adhesive or a mastic. Release liner are available in different colors, with or without...
- dieDie (manufacturing)A die is a specialized tool used in manufacturing industries to cut or shape material using a press. Like molds, dies are generally customized to the item they are used to create...
-cutting materials into finished parts or labels. - printing services
- Roll slittingRoll slittingRoll slitting, also known as log slitting, is a shearing operation that cuts a large roll of material into narrower rolls. The log slitting terminology refers back to the olden days of saw mills when they would cut logs into smaller sections. They would also use these saw mills to cut iron rods...
of wide webs into narrow webs or coils - Laminating services
- Vacuforming