Prior to the 1960s
the only winder available to paper mills were two drum winders.
Although the two drum winder served the industry well for the
times, it had a serious limitation-it did not have the ability
to wind very large rolls. Large jumbo reels were sent directly
from the paper machine reel to the subsequent finishing operations
such as the off-machine coater, supercalender or shipping roll
winder. Because many of the reels could have paper machine breaks
or poor paper, the subsequent finishing operations were inefficient
due to stopping to cull out poor paper or splicing paper machine
breaks in the reel.
Some
mills attempted to use a 2drum winder specially modified with
core shaft holders that could accommodate reel spools. In this
way they could rewind machine reels that had breaks or poor paper
and send an improved though smaller jumbo to the subsequent in-house
finishing operations. Editing the jumbo in this manner did improve
the efficiency of the subsequent operations but limited the size
of the jumbo going to the operations which had it's own negative
impact on process productivity.
In
the very late 50's and early 60's a "rereeler concept"
developed. The rereeler essentially was a paper machine reel without
primary arms and trim slitters mounted ahead of the reel drum
to trim the deckle edge of the jumbo. The rereeler was a batch
operation making it possible to stop and splice paper machine
breaks and remove off-quality paper. This resulted in a large
jumbo reel (sometimes referred to as a "bull-eye" reel)
with few imperfections going to the in-house finishing operation.
The rereeler, winding on reel spools, had the ability to produce
an "edited" jumbo as large as the paper machine reel
of improved structure. . The rereeler greatly improved the finishing
line efficiency and permitted larger and larger jumbos to be sent
down the line. In a short time most coated paper mills used rereelers
between the paper machine reel and off machine coater or super
calenders to make large bulls-eye" reels for the in-house
finishing operations.
With the knowledge
that centerwind drives greatly improve the winding capability
of the rereeler, it is not uncommon to see rereelers equipped
with a centwerwind drive which not only improves the jumbo structure
but also reduces waste and permits winding larger jumbos. Although
now taken for granted, the rereeler was a tremendously important
development that had a significant impact on all in-house finishing
operations, greatly improved the production capability of the
shipping roll winder and indirectly effected the runnability and
waste reduction of the end user of the paper.
Things started to
happen rapidly in the early 60's in the winding area. The changes
in paper properties had a great impact on the ability of two drum
winders to produce well-structured shipping rolls in the widths
and diameters that printers and converters were requesting. The
lighter weight and denser sheets were adding to the winding problems.
It was obvious that a new concept winder was required.
The ability of paper
machine reels (and rereelers) to wind large full width jumbos
did not go unnoticed. In a short time the rush was on by winder
builders to adopt the "paper machine reel" concept for
shipping roll winding. The new concept winders were called "duplex"
winders, the name referring to the fact the duplex winder wound
shipping rolls on alternate sides of the winder drum(s).
The earlier duplex
winder concept was called a "core support winder" because
like it's mentor, the paper machine reel, it supported the full
weight of the winding roll on a core shaft. Unlike the paper machine
reel, the shipping roll winders used intermediate slitters and
wound rolls alternately on opposite sides of the drum on shipping
roll cores. Here again was a development that would have positive
repercussions all through the printing papers segment of the paper
industry.
One
of the first duplex winders was a single drum version. This concept closely emulated the paper machine reel in that it used a single
drum for winding. The very first of this generation of winders
was called the MIR which stood for Multiple Individual Rewinds.
The single drum version was produced in several specific designs
by several winder builders. The early versions of the single drum
duplex winder using fixed stations to support the winding roll
did not have centerwind drives but modern versions are now available
with this feature.
Another
duplex core support winder produced in the early 60's was the
two drum version. This in effect was a two drum winder turned
on it's side. The two winder drums were tied together with a belted
arrangement called a "harmonic drive." The harmonic
drive arrangement produced a torque differential between the top
and bottom winder drum giving it the full TNT roll structuring
capability found so useful on the two drum winders.
Still another version of the core support winder was produced
that used pivoted arms as opposed to stationary stands to support
the winding rolls. This concept had full centerwind capability
using hydraulic or electric motors, depending on the builder. The hydraulic version was the first duplex concept to have
individual centerdrives on both ends of each individual roll of
the set.
As
paper properties continued to change and printers and converters
demanded wider and larger diameter rolls with better runnability
in the pressrooms to improve their operating efficiency, core
support winders started to fall on hard times on some applications.
When winding wide, large diameter rolls of roto papers, the additional
weight supported by the core shaft was resulting in wound roll
defects near the core. A new generation of duplex winders called
drum support duplex winders were developed. The core at start
was held in place by the chucks and rider rolls and supported
by the winder drum. As the roll builds during winding, the roll
weight load is shared by the core chucks and winder drum. The
rider rolls generally lift off the set at about 10 to 12"diameter.
Roll structuring is programmed through rider roll load, core chuck
relieving or load, tension control and centerwind torque if available
.
The
first of this generation of duplex winders used a relatively large
center drum and overhead mounted rider rolls and core chuck holders.
Roll structuring was accomplished by tension control and pneumatic
control of rider roll load and core chuck load and relieving programs.
The early versions of this concept did not have centerwind drives
but the feature was available in later models. The core support
winders rely heavily on computerized control of the winding variables.
One of the available core support duplex winders uses a large
paper carrying roll between a pair of horizontal winder drums.
This particular winder was initially furnished with a single electric
centerwind motor at each winding station to provide torque control
during winding.
The final drum support winder to be reviewed uses a single winder
drum. Each roll of a set is supported by a pair of pivoting arms
that contain integral electric motors within the arm framework.
The integral motor in each arm results in a minimum electric drive
size profile in the cross machine direction permitting narrow
slits across the full width of the winder face. The builder suggests
that the use of centerwind motors on each end of the winding roll
results in symmetrical torsioning of the winding set with a maximum
torque availability.
It is obvious that
each of the winder applications shown in this scrapbook have their
own unique advantages and disadvantages. Application to a certain
extent is generally grade specific. Important considerations are
minimum slit width and productivity potential. It is universally
recognized that the productivity of a duplex winder does not compare
favorably with that of the two drum winder. Recent innovations
in duplex winder designs have made great improvements in the production
capability of all duplex winder concepts, The winders illustrated
have demonstrated their success in winding high quality shipping
rolls for the grades they are designed to handle. Most are available
in manual or automated designs for flexibility to accommodate
structure and production demands.
This type of winder
appears to be in a steady stream of upgrading to wind heavier,
high quality shipping rolls and increased productivity.
This scrapbook
contains conceptual sketches of winder configurations in present
use in the Pulp & Paper Industry. The sketches are not drawn
to scale and use generic sheet runs and are not intended to represent
equipment as designed and sold by winder manufacturers. For specific details, arrangements, specifications
or other issues concerning the concepts illustrated, contact a
manufacturer that produces such concepts.
In
the very late 50's and early 60's a "rereeler concept"
developed. The rereeler essentially was a paper machine reel without
primary arms and trim slitters mounted ahead of the reel drum
to trim the deckle edge of the jumbo. The rereeler was a batch
operation making it possible to stop and splice paper machine
breaks and remove off-quality paper. This resulted in a large
jumbo reel (sometimes referred to as a "bull-eye" reel)
with few imperfections going to the in-house finishing operation.
The rereeler, winding on reel spools, had the ability to produce
an "edited" jumbo as large as the paper machine reel
of improved structure. . The rereeler greatly improved the finishing
line efficiency and permitted larger and larger jumbos to be sent
down the line. In a short time most coated paper mills used rereelers
between the paper machine reel and off machine coater or super
calenders to make large bulls-eye" reels for the in-house
finishing operations.
One
of the first duplex winders was a single drum version. This concept closely emulated the paper machine reel in that it used a single
drum for winding. The very first of this generation of winders
was called the MIR which stood for Multiple Individual Rewinds.
The single drum version was produced in several specific designs
by several winder builders. The early versions of the single drum
duplex winder using fixed stations to support the winding roll
did not have centerwind drives but modern versions are now available
with this feature.
Another
duplex core support winder produced in the early 60's was the
two drum version. This in effect was a two drum winder turned
on it's side. The two winder drums were tied together with a belted
arrangement called a "harmonic drive." The harmonic
drive arrangement produced a torque differential between the top
and bottom winder drum giving it the full TNT roll structuring
capability found so useful on the two drum winders.
Still another version of the core support winder was produced
that used pivoted arms as opposed to stationary stands to support
the winding rolls. This concept had full centerwind capability
using hydraulic or electric motors, depending on the builder. The hydraulic version was the first duplex concept to have
individual centerdrives on both ends of each individual roll of
the set.
As
paper properties continued to change and printers and converters
demanded wider and larger diameter rolls with better runnability
in the pressrooms to improve their operating efficiency, core
support winders started to fall on hard times on some applications.
When winding wide, large diameter rolls of roto papers, the additional
weight supported by the core shaft was resulting in wound roll
defects near the core. A new generation of duplex winders called
drum support duplex winders were developed. The core at start
was held in place by the chucks and rider rolls and supported
by the winder drum. As the roll builds during winding, the roll
weight load is shared by the core chucks and winder drum. The
rider rolls generally lift off the set at about 10 to 12"diameter.
Roll structuring is programmed through rider roll load, core chuck
relieving or load, tension control and centerwind torque if available
The
first of this generation of duplex winders used a relatively large
center drum and overhead mounted rider rolls and core chuck holders.
Roll structuring was accomplished by tension control and pneumatic
control of rider roll load and core chuck load and relieving programs.
The early versions of this concept did not have centerwind drives
but the feature was available in later models. The core support
winders rely heavily on computerized control of the winding variables.
One of the available core support duplex winders uses a large
paper carrying roll between a pair of horizontal winder drums.
This particular winder was initially furnished with a single electric
centerwind motor at each winding station to provide torque control
during winding.
The final drum support winder to be reviewed uses a single winder
drum. Each roll of a set is supported by a pair of pivoting arms
that contain integral electric motors within the arm framework.
The integral motor in each arm results in a minimum electric drive
size profile in the cross machine direction permitting narrow
slits across the full width of the winder face. The builder suggests
that the use of centerwind motors on each end of the winding roll
results in symmetrical torsioning of the winding set with a maximum
torque availability.