Last year, we introduced our state-of-the-art tube winding machine to transform how we deliver heavy wall cores to our customers. After half a year of operation, the results speak for themselves – faster turnarounds, superior quality, and the ability to handle urgent orders that would have been impossible with our previous equipment.
What Makes Our New Winder Different
The machine operates in two key phases: Phase 1 handles reels and winding, whilst Phase 2 manages the cutting process. This dual-phase approach has revolutionised our production capabilities.
Advanced Multi-Ply Construction
The secret to achieving exceptional radial strength lies in precise control over multiple factors. Our new winder allows us to manage ply count, blade speed, support roller controls, and winding speed with unprecedented accuracy. What used to require extensive manual adjustments and experienced operators, can now be achieved quickly through simple set-up technology.
The top-of-the-range reel stand and festoon system has virtually eliminated splicing issues – reducing them by 90%. This means fewer production stoppages and more consistent output for our customers.
Dual-Blade Cutting Precision
The multi-knife unit cuts between blades, delivering exceptional length control and accuracy. Length changes can now happen without stopping the machine – a massive improvement over our old system that required up to 30 minutes of downtime for each adjustment.
With several length changes possible daily, this automated set-up tech saves hours of production time. The blade depth settings are achieved in one go, eliminating waste from multiple adjustment attempts.
Direct Benefits for Our Customers
Dramatically Reduced Lead Times
The combination of fast set-ups and fewer stoppages means we can produce more cores within each production shift. What once took days can often be completed in hours.
Consistent Quality You Can Count On
Our improved glue tank and guide system ensures every core meets exacting standards. The predictability factor has transformed our operations – we can guarantee that X number of cores will be produced to the correct standard over Y hours. Specifically, this machine, known as a multiknife winder, cuts cores between two blades, giving a higher level of accuracy on the cut length relative to lower cost single knife machines.
This consistency translates directly into reliability for our customers’ production schedules.
Increased Capacity for Larger Orders
Industrial Packaging now have two Multiknife winders alongside our two single knife machines increasing our capacity by + 25% and mitigating any breakdown risk. This translates to reliable, quality supply to customers. Better Delivery Performance
The enhanced capability has helped us reduce lead times and improve our On Time In Full (OTIF) delivery performance. When our customers need cores, they can count on us to deliver.
Real-World Impact
Recently, one of our customers underestimated their core consumption and faced a potential crisis with their biggest client. Thanks to our new winder’s capabilities, we delivered a complete load of heavy wall, high-strength cores within 72 hours – saving them from a potentially devastating situation.
This kind of rapid response wasn’t possible with our previous equipment.
Looking Forward
The new winder has proven that investing in advanced technology directly benefits our customers. Fast set-ups, consistent quality, increased capacity, and reliable delivery times aren’t just internal improvements – they’re competitive advantages we pass on to every client.
Whether you need standard cores or urgent, high-spec. orders, our enhanced capabilities mean we’re better positioned than ever to support your business needs.