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Sensor Products Inc. USA is hosting a seminar in Birmingham, Uk on the 25 - 26th January 2012, the seminar highlights the Principles of Winding & Slitting.

This seminar will help you understand your existing winding and slitting processes so you can optimize them and reduce the problems – both real and potential by immediately applying proven best practices. Major areas of focus include web handling principles, understanding the structure of a wound roll, equipment used in winding from simple to complex and the many type of winders on the market and where and how they are used, all the ways winding can go wrong and how to avoid them and solutions if you can’t, and the three conventional slitting methods (razor, crush, and shear) and slitter operations efficiency. These topics will be addresses at many levels, providing rules of thumb and the theory behind them.

Who Should Attend
Anyone working with supervising operators or managing operation of web machinery will benefit from this unique course. This includes product/process designers, process engineers, quality personnel, sales/service, maintenance and lead operators. Understanding winding and slitting is also vital to anyone working with webs and web processes, including material suppliers and equipment and component suppliers.

About the Instructor
Chris Watson, President of Watson consulting & Assoc., and former president of Kroenert Corp. a world leader in web handling, coating, and drying technology, began working with web handling issues and helping companies resolve them in 1971. With over 20 years consulting on hundreds of projects dealing with a myriad of issues and materials, Chris continues to help Fortune 500 companies and small startup companies.

Chris has lectured for over 30 years at conferences in the US and Europe on web handling technology, coating methods, drying technology, paper physics, and specific issues related to customers’ needs. Realizing that learning curves can be significantly shortened and costly mistakes avoided by consulting with experts who "have been there before", US and foreign companies involved in web coating and converting have attended in-house conference and national conferences to hear Chris Watson's involvement with web coating technologies goes back to the 1960's.

After graduating with a degree in chemistry from The King's College, he was made Project Leader for coated products at Riegel Paper. During this time, he also did graduate work in Polymer Science. Watson has been a successful independent consultant in a wide variety of web related issues including the field of silicone, pressure sensitive, and various web-coating and converting processes for over 25 years. He has advised such firms as Fasson, Coated Products, Mystic Tape, KDP in France, Sterling Coated Products in England, Renker in Germany, OpSec Banknote & High Security in Newcastle UK, Lohja in Finland, and major machine builders in the US.

• Understand what center and surface winding is and their best use
• Understand five benefits of gapped and nipped winding
• Understand the importance of how air enters a wound roll and problems with too little or much
• Understand rewind slip clutches and learn how to wind multiple rolls on one shaft and when differential winding is needed
• Understand what causes the most common wound roll defects and how to remedy them
• Understand how winding contributes to web bagginess and how to minimize it
• Understand what is the best setup and application of all slitting methods and why

• Center and surface winders
• Gap and nipped winders
• Differential winding
• Roll transfers
• Un-winders
• Specialty winding

Slitting
• Fracture Mechanics
• Razor Slitting
• Crush Slitting
• Rotary Slitting
• Shear Slitting
• Slitting in Registration (Stripe Slitting)
• Alternate Slitting Methods
• Slitting Operational Efficiency

The Process of Winding
• The goals of winding
• Winding and winder definitions
• Building a roll structure
• Center and surface winding
• Gap and nipped winding
• Roll dynamics

The Solutions of Winding
• Wrinkling during winding
• Too tight or too loose
• Scratching & debris
• Roll slippage
• Shifted layers
• Buckling within a roll
• Deformations
• Gauge variation defects
• Baggy webs

Below you can download the course brochure and syllabus

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Sigma-Nip^® - an electronic nip analysis system, calculates and records nip width at multiple points across your rollers face length in real-time with unprecedented speed, accuracy and repeatability. The new Sigmanip^® system is not only more accurate, but can handle higher pressures than ever previously attainable.

Sigma-Nip^® presents a revolution in quality control. Now, for the first time ever the technician is able to accurately, efficiently and economically measure roller profiles and alignment condition. Sigma-Nip^® consists of a series of thin-film resistive ink pressure transducers on a carrier sheet. As this carrier sheet is loaded in between your rollers the Windows based software assimilates the readings into easily interpretable graphical images - all in real-time.

What Is Sigma-Nip^®

Sigma-Nip^® consists of a series of sensor elements that are placed in between two contacting rollers. Immediately upon closing of rolls, the sensor begins recording precise nip width measurements allowing you to instantaneously determine whether your rollers are aligned properly and are squeezing together sufficiently. Sigma-Nip^® is a real-time system. What that means is that your roller adjustments can be made WHILE the sensor is actually in the closed (non-rotating) nip. This allows for unprecedented flexibility and speed.

Designed For Productivity

Sigma-Nip^® comes complete with everything you need to quickly and accurately take nip impressions. Sigma-nip^®’s software is so intuitive and user friendly within minutes even an inexperienced user will benefit from it’s powerful reports.

Sigma-Nip^® is designed with the intention of being used during routine maintenance or set up and is quickly disposed across the roller surface by just one person. The system is modular and portable and quickly interfaces to the USB port on any standard Windows laptop.

Why Use Sigma-Nip^®

Proper roller alignment and pressure level are critical for both print clarity and web control. An evenly loaded roller set is much less likely to cause costly web breaks and sheet “walking”, wrinkles, or fold-overs. Simply by virtue of routine tests, Sigma-Nip allows the user to greatly extend blanket life.

Sigma-Nip^® Technology

Through the application of sophisticated mathematical algorithms, Sigma-Nip^® is able to discern the contact profile of the machine’s cross direction with a higher degree of accuracy never before attainable. Each sensor is individually calibrated, serialized and carefully assembled to exacting tolerances. The sensor is designed to withstand repeated high pressures, conform to radiused surfaces and routine exposure to grease, liquids and inks.

What people are saying about Sigma-Nip^® ...

"Sigma-Nip^® has come a long way from concept to a reliable, easy to use nip profile measuring tool. It has successfully bridged the gap between conventional carbon paper impressions and the first generation of electronic nip devices. Being able to save and review the entire real-time data from nip closing to nip opening is extremely useful, however, the ability to correlate accurate nip width data to roll deflection is an exceptional benefit." — Mike Stoltz, Metso Paper USA

"Sigma-Nip^® is an extremely helpful tool for troubleshooting in printing presses and has saved my colleagues and I significant amounts of time. It allows us to assess what is happening where the actual printing takes place and quickly get to the source of the problem. This is a new tool for us and the industry, but I foresee more and more printers starting to use this system as people begin to see its advantages." — Don Jordan, Abitibi Consolidated

Maintaining heat within certain parameters between contacting platens and rollers is critical in several converting and printing applications. For that reason, Sensor Products Inc. has developed Thermex^® surface temperature distribution film.

Thermex^® is an economical thin film that can be used in virtually any application to monitor heated contacting rollers and presses from 200° to 300°F (93° to 149°C). Maintaining proper thermal contact across the interface of vacuum and flat web-type machines and lamination presses are among uses for this film.

Upon exposure to heat, Thermex^® changes color instantaneously and permanently to reveal temperature distribution between any two contacting surfaces. The intensity of this color change directly relates to the temperature it was exposed to enabling Thermex^® to reveal spot high or low temperature zones and minute surface variations.

While the used Thermex^® material may be saved for archival purposes, its low cost renders it inherently disposable.  A sheet of Thermex^® which is available in 14” by 17” (35.6 by 43.2 cm) format costs $25.00 or $299.99 for a pack of 25 sheets. It can be easily trimmed for smaller applications or custom cut to defined dimensions.

New applications for Thermex ^®are being discovered daily.  Common applications include heat sealing, lamination/press, converting, metallurgical welding, ultrasonic welding, heat sinking, and clutch/brake interfaces.

Post processing analysis of Thermex^® is available for temperature fluctuations that need to be analyzed with great precision.  For more information or to order Thermex^®, call Sensor Products Inc. 1.973.884.1755 email, This email address is being protected from spambots. You need JavaScript enabled to view it. or view sensorprod.com/thermex.  Many items from Sensor Products are available in their shopping cart online.

Mold-Align® is a unique, affordable and easy to use tool that reveals pressure distribution between mold platens.

Of the hundreds of variables involved in injection molding, clamping mechanisms and platens often get less attention than they deserve. Good clamp performance is critical to minimize cycle times, optimize part quality, and maintain process consistency. Alignment and uniformity of the mold halves, platens, and clamping system is therefore critical. When an alignment problem stems from the mold parting line, the platens, or the clamping mechanism and tie bars, the results can be unnecessary machine wear, mold damage, broken tie bars, mold flash, and scrap parts.

One way to ensure proper mating of the tool halves at the parting line is simply by having a level molding machine and parallel platens. Leveling a machine requires three machinist levels. If you have shorts and flash, you could have a mold or clamping alignment problem.

This may not be the case if you are running a high-speed, thin-wall product—the problem may be simply not enough clamp force. To help establish whether flash stems from a mold or clamp alignment issue, check parting-line mating. In one typical check for uniform clamp pressure at the parting line, bluing agent applied to one mold half will transfer to the other if there is contact at the parting line.

But it will not distinguish between low or high touch forces. More detailed information can be obtained with Mold-Align® paper, which changes color relative to the amount of contact force. Mold-Align® is an extremely economical and practical solution for determining proper mold alignment. Mold-Align® is a self contained (single sheet) paper that is quickly implemented, requires no training, and reveals a high resolution image of pressure distribution and void spots between mold plates.

SPECIFICATIONS

For more info please contact:
Vadim Shalyt
Sr. Application Specialist
Sensor Products Inc. USA
300 Madison Ave.
Madison, NJ 07940
1.973.428.8985 (phone)
1.973.495.9800 (cell)
1.973.884.1699 (fax)
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Sigma-Nip^®, is a technologically advanced electronic nip analysis system from Sensor Products Inc. that measures roller profiles and diagnoses roll alignment with unprecedented speed and cost-effectiveness.  This sensor system, which records nip width, renders obsolete time-consuming and inexact tools such as carbon paper and embossed foils.  When Sigma-Nip^® is used, loading problems, skewing, and crown deficiencies are quickly exposed.  It is more accurate, more durable, and has a more powerful software user interface than any of its predecessors. UPM, Metso Paper, Dupont Nonwovens, PGI Nordlys and Thai Paper are some of the leading companies around the world that have purchased Sigma-Nip^®..

Sigma-Nip^® consists of a chain of sensor elements and Windows-based software.  The new sensors have been improved to withstand repeated high pressures and temperatures as well as routine exposure to grease and solvents. When placed between two contacting rollers, the sensors capture data and ultimately record and assimilate nip width readings on a laptop while it is being viewed.  Adjustments to rollers are made in real time while the sensors are in the closed, (non-rotating) nip.  Easy-to-interpret statistical data and graphical displays, which are being transmitted via wireless or through a USB port, update continuously as technicians perform their tests and adjustments.

Taking only minutes to deploy across the roller face by just one person, Sigma-Nip^® is useful for ongoing maintenance, as well as during equipment setups and shutdowns.  As a quality control tool,  Sigma-Nip^® facilitates evenly loaded roller sets that are much less likely to cause web breaks and costly down time. It improves web control and print quality by reducing uneven paper pulling, which can lead to sheet walking, wrinkles, jams and misregistration. By virtue of routine tests, Sigma-Nip^® allows the user to greatly extend blanket life.

"Sigma-Nip^® has come a long way from concept to being a reliable, easy-to-use nip profile measuring tool,” according to Mike Stoltz of Metso Paper.   “Being able to save and review the entire real-time data from nip closing to nip opening is extremely useful, however, the ability to correlate accurate nip width data to roll deflection is an exceptional benefit."

Sigma-Nip –2

Sigma-Nip^® is designed for maximum versatility. The system is portable and comes with its own carrying case. Depending on the number of sensors ordered, the same sensor chain can be used to measure different sized rolls.  Nip widths from 0.15 in. (0.38 cm) to 9 in. (22.9 cm) can be measured, and pressures from 40 PSI (2.8 kg/cm²) to 3,000 PSI (211 kg/cm²) can be withstood, making Sigma-Nip^® potentially usable throughout the machine.  Large pulp and paper rolls, small converting rolls as well as calendar stacks are all potentially measurable by Sigma Nip. Face lengths of 35” – 443” (90 cm – 1,125cm) can be accommodated.

Minimal computer knowledge or training is needed since the system prompts users through the few steps needed for installation and set up. Software enhancements include a Comparison Mode, where up to three nip width readings can be viewed simultaneously, and an Alignment Tool, which instantly draws a line to indicate nip width variations.

, or to schedule a demonstration, contact Sensor Products Inc. at 1.800.755.2201 or 1-973-884-1755 (USA), e-mail This email address is being protected from spambots. You need JavaScript enabled to view it., or visit the website www.sensorprod.com/sigmanip.

About Sensor Products Inc. (USA)

Headquartered in New Jersey and established in 1990, Sensor Products Inc. is a world leader in the manufacture and distribution of tactile pressure sensing solutions. Their customized and off-the-shelf products are installed within all of the Fortune 500 industrial companies as well as thousands of smaller manufacturing firms. Their sensors are used in applications as diverse as tire testing to semiconductor manufacturing and from R&D labs to space missions. Additionally, Sensor Products provides in-house and on-site stress and pressure mapping analysis, as well as a variety of regional technical seminars.

During tough economic times it is tempting to reduce quality control to cut costs in maintaining rollers for papermaking, printing and converting. However Dolph Beyer, an engineer with Mohawk Fine Papers, asserts doing this is actually counterproductive. He has determined using Pressurex® pressure indicating sensor film as a quality control tool to aid in alignment and diagnose the condition of his rollers actually decreases costs and significantly improves product quality.

"By taking nip impressions with pressure indicating film every couple of weeks, we are able to extend roll life by a few months in many cases," says Mr. Beyer." By examining the roll nip impressions we can more accurately determine where we are in the life cycle of some of our rolls. This helps to pinpoint more accurately when rolls need to be changed and may indicate needed roll grind improvements or cover material changes to help extend roll run life cycles. Extended run cycles reduce the re-grind frequencies and therefore extend the cover life." This quality control measure not only lowers costs for the replacement of these covers, but also minimizes equipment downtime."

Pressurex® reveals pressure from 2 - 43,200 PSI (0.14 - 3,000 kg/cm2).
When placed between contacting rollers, the sensor film instantaneously and permanently changes color directly proportional to the actual pressure applied. Precise pressure magnitude is then easily determined by comparing color variation results to a color correlation chart (conceptually similar to interpreting Litmus paper). Variations in pressure that lead to defects in papermaking, converting and printing can be quickly and accurately detected and corrected -- improving yield, decreasing scrap, and increasing productivity.

By examining pressure variations in the nip, corrections in alignment and crown profiles can be made. The film is effective on virtually all roller compositions and surfaces. A visual pressure mapping profile of an engraved pattern or drilled roll can be effortlessly produced that exposes minute surface defects and other imperfections.

Pressure indicating sensor film is cited by Mr. Beyer as being especially helpful with calendar rolls, which are swim rolls that have mechanisms to allow the center of the rollers to exert a different level of pressure. "Similar to crown rolls, swim rolls need to be carefully monitored to ensure even and exacting pressure is being applied to achieve optimum nip conditions," says Mr. Beyer. "We use the film to create just the right nip and improve the roll shape and crown to deliver better sheet uniformity.

Mohawk Fine Papers uses Pressurex® to take static nip impressions on their press section and dynamic nip impressions on their calendars. Dynamic nip impressions are inspected for uniformity and static nip impressions for uniformity and nip pressure. Image results of Pressurex® are archived and used as a control to compare tools and processes.

Pressurex® is extremely thin (4 to 8 mils) and flexible, which allows it to conform to curved surfaces. It is ideal for invasive intolerant environments and tight spaces not accessible to conventional electronic transducers. While recommended for tests in non-operating conditions, the sensor film can be used at temperatures exceeding 200 Fº (93 Cº) for brief intervals.

For a free sample of Pressurex® in your desired range, contact Sensor Products Inc. at 1.973.884.1755 (USA), email This email address is being protected from spambots. You need JavaScript enabled to view it. or visit www.sensorprod.com/sample.