Herma has introduced a new optional cutting system for its AutoSplicer, extending automated roll-change capability in label printing to rolls whose web is firmly attached to the core. The system enables uninterrupted roll changes even for label roll designs that previously required manual intervention at the end of a roll.
The AutoSplicer uses two roll unwinders: while the label web from one roll is being processed, a second roll is prepared for the next changeover. As the active roll nears its end, the system splices its web to the prepared web of the reserve roll, allowing the labeling process to continue uninterrupted while the operator replaces the empty roll and prepares the unwinder for the next change.
Previously, this process required the label web to detach from the core on its own at the end of the roll, which is possible with certain roll designs but not others. With rolls where the label web is firmly connected to the core, allowing the web to run out completely can create unwanted tension and cause the web to become damaged or tear. The new cutting system addresses this by cutting the label web in a controlled manner, without manual intervention, before the roll is fully used. This allows the AutoSplicer to complete the roll change without interruption regardless of roll design. Because the cutting system is needed only for these roll types, Herma offers it as an option. The AutoSplicer also includes a newly integrated HMI system and GUI design, which the company said simplifies machine control and process visualization for operators.
A calculation provided by Herma illustrates the potential productivity impact of uninterrupted roll changes: with ten roll changes per shift and an average changeover time of three minutes, manual roll changes result in 30 minutes of downtime per shift, or about 90 minutes per day across a three-shift operation. “With 47 production weeks, this can amount to more than 350 hours per year,” said Max Kunert, head of project and product management at Herma. “The actual savings naturally depend on the production speed, the roll size, and the specific system configuration. However, the example shows how quickly regularly recurring interruptions can become a significant factor affecting productivity.”
According to the company, automated roll changes standardize processes, reduce manual intervention, and improve production planning, an advantage it said is particularly significant in high-performance labeling lines with high web speeds and frequent roll changes. The company stated that even at web speeds exceeding 110 meters per minute, the splicing technology ensures a secure connection of the label webs and a stable, material-friendly process. The AutoSplicer handles paper and film labels as well as transparent or multi-layer label materials, and the company said it can be integrated into existing labeling systems without extensive modifications or lengthy training.
“The AutoSplicer with the new cutting system demonstrates how Herma takes a holistic view of the entire labeling process,” Kunert said. “Our goal is to consistently automate not only the actual labeling, but also the material feed and related handling processes.”