Slitter and rewinder in the packaging industry: the secret to improving efficiency and reducing costs

The application of slitter rewinder in the packaging industry has significantly improved production efficiency and material utilization through its efficient and accurate processing capabilities, while reducing labor costs and scrap rates. Here are its core benefits and application details:

First, the core function of the slitting and rewinding machine

1. Slitting

◦ Cut large rolls of raw materials (such as film, paper, aluminum foil, non-woven fabrics, etc.) into multiple rolls of narrow materials according to demand.

◦ The accuracy can reach ±0.1mm, avoiding edge burrs or waste caused by traditional cutting.

2. Rewinding

◦ Re-roll the material, adjust the tension and tightness, ensure that the coil is neat and uniform, and adapt to the subsequent automatic packaging equipment.

Second, the key technology to improve efficiency

1. High-speed automated production

◦ Modern slitter rewinders can reach speeds of more than 1000 m/min, which is much higher than manual operation (traditional methods are inefficient and error-prone).

◦ Automatic control system (such as PLC + touch screen) realizes one-key specification change and reduces downtime.

2. Precise tension control

◦ Magnetic particle brake or servo motor is used to control the tension to avoid tensile deformation or wrinkles of the material and reduce the defective rate.

3. Intelligent detection system

◦ Integrated CCD camera or laser sensor to detect material defects (such as bubbles, scratches) in real time, and automatically mark and reject defective parts.

Third, the secret of reducing costs

1. Maximize material utilization

◦ By optimizing the slitting scheme (such as CNC knife arrangement system), the material utilization rate can reach more than 99% by reducing the leftover material.

◦ Precise control of roll diameter during rewinding to avoid over-packaging (e.g., end products such as plastic wrap and tape).

2. Reduce human dependency

◦ 1 piece of equipment can replace 5-8 workers, especially in areas with high labor costs.

◦ Operators only need to monitor and enter parameters, reducing training effort.

3. Waste recycling and energy optimization

◦ Automatic winding or crushing and recycling of offcuts, and some models are equipped with energy-saving motors to reduce long-term operating costs.

Fourth, typical application scenarios

1. Flexible packaging industry

◦ Slitting PE/PP film and composite film are used in the production of food bags and express bags.

2. Labels & Tapes

◦ Cut large rolls of self-adhesive material into finished labels or tapes.

3. Hygienic materials

◦ Slitting non-woven fabrics, release paper (such as masks, sanitary napkins raw materials).

4. Industrial packaging

◦ Handle protective materials such as aluminum foil and bubble wrap to meet the needs of e-commerce packaging.

Fifth, industry trends and innovations

1. Intelligent upgrade

◦ Integrate MES system to monitor equipment status, energy consumption and output in real time to achieve predictive maintenance.

2. Multi-functional integration

◦ Slitting + printing + rewinding machine to reduce intermediate links (such as one-time molding of labels).

3. Eco-friendly adaptation

◦ Support the processing of degradable materials (PLA, PBAT) to meet the needs of green packaging.

Sixth, the key points of choosing a slitting rewinder

• Material adaptability: Different materials (e.g. brittle film vs. thick cardboard) need to be corresponding.

• Accuracy and speed: Servo drive models are preferred for high-precision requirements (such as electronic component packaging).

• Scalability: Reserved IoT interfaces to facilitate the docking of future digital factories.

Through the application of slitting and rewinding machines, packaging companies can significantly shorten the delivery cycle and reduce the cost per piece, especially in the market environment of increasing customized orders, its flexibility and efficiency advantages are more prominent.