Better Web Control Newsletter - November 2013

In This Issue:
NEW – X Series Load Cells
Achieve More – Montalvo Upgrades and Retrofits

NEW X Series Load Cells 

Designed for applications utilizing either a cantilever roller (XN) or a pulley (XR), the all new X Series perfectly blends versatility, functionality, and performance.

Use what you have:
Capable of accepting your currant rollers or pulleys (XB body only, the X Series can turn a neutral part of your line into a tension measurement powerhouse or simply upgrade your current load cell.

Or customize it:
Whether you need a cantilever roller or pulley or a specific diameter, profile, material, finish, you name it, we customize the X Series to meet your exact needs.

A Dual Parallel Beam eliminates web drift while offering full bridge capability. Other features include:

• Leading tension sensing sensitivity
• 100% stainless steel body
• 2 Mounting Options – Standard or Flange
• Mechanical Variance Compensation
• Multiple Load Ranges
• and more

To learn more about the X Series Load Cell visit the X Series Webpage

Achieve More – Montalvo Upgrades & Retrofits 

It never hurts to ask! Talk to a Montalvo Applications Specialist and get a free Application Review to see Where your machine could achieve more!
In today’s competitive landscape machines in current use need to be able to compete with new machines. What many people aren’t aware of is that a simple upgrade to the tension control components of your machine can make your machine run practically new.

• Faster line speeds
• Higher quality end product
• Reduced waste
• Decreased downtime
• Lower operating costs

These are just some of the benefits of a tension control upgrade.

Montalvo has performed upgrades & retrofits on practically every type of application in the industry. Our vast industry knowledge and experience has earned us the reputation as a primary source for expert advice in adding capability, efficiency, productivity and profitability to your machines.

Contact Us today with Your Application Information

In This Issue:
Video: V Brake Installation
Here for You

Video: V Brake Installation

We’ve often talked about just how easy it is to install and maintain the V Brake. The V Pad Productivity video showcased the ease of maintenance, and now we showcase the ease of installation.

The combination of ease of installation, ease and speed of maintenance, the torque range, and performance, make the V Brake one of the most cost effective, productivity increasing and long lasting brakes in the industry.

Over the service life of any tension brake the V Brake has truly set itself apart.

Check out the video to see just how easy it is to install Montalvo’s V Brake!

Here for you! 

We’ve recently launched our new Facebook page. With the ever changing landscape of social media, Montalvo is committed to ensuring we are readily available to you, however you prefer to communicate. In combination with web, phone, email, fax, and our internal & external worldwide Applications Specialists network our social media presence on Facebook, Linkedln, Google+, and YouTube guarantees that

Montalvo is Here for You!

Check out and ‘Like’ or ‘Follow’ our new Facebook page!

Add Montalvo to your Circle and + 1 us on Google+

In This Issue:
Video: ES Load Cell Sensitivity
1 Week Load Cell Delivery

Video: ES Load Cell Sensitivity

Montalvo manufacturers some of the industry’s most sensitive load cells with leading repeatability ratings.
See exactly what that means and what it means for you with the ES Load Cell Sensitivity video demonstration.

Check out the video here

1 Week Load Cell Delivery

Exceptional product quality & performance delivered to you within 1 week for North American markets and within 2 weeks for all other markets (standard load ratings apply).

Montalvo’s ES-I Dead Shaft-Idler Style load cells feature industry leading sensitivity and repeatability, a 100% stainless steel body, IP-54 (dust proof) rating and unique mechanical variance compensation.

ES-I load cells are also available in 3 different mounting configurations:

• Standard
• Flange
• Split pillow block

ES Series Load Cells are capable of detecting a wider range of tension changes and thus feature standard load ratings that are effective for a majority of applications (non-standard load ratings are still available).

Standard load ratings include:

• Size O: 50 lbs (250 N)
• Size 0: 150 lbs (750 N)
• Size 2: 150 lbs (750 N)
• Size 2: 500 lbs (2500 N)

For example, the Size 0, 150 lb (750 N) load cell, repeatably  detects tension changes from 0.44 lbs (1.996 N) up to 150 lbs of tension.

A chart of complete load cell testing data and effective tension ranges can be seen here.  Check out the ES-I Dead Shaft-Idler product page for a full list of features, datasheets, drawings, mounting styles, load ratings and more.

In This Issue:
Using Clutches for Superior Center Winding Tension Control
Product Spotlight: Micro Rotary Union

Using Clutches for Superior Center Winding Tension Control 

Excerpt: ” … Clutches are not often chosen to control tension on center winders because their proper application and the advantages of using a clutch with a motor are usually not understood.

Usually, when one finds a clutch-controlled center winder, the clutch is “geared in” to run 50 RPM faster than line speed at core. The clutch is usually driven by a constant RPM AC motor, and therein lays the crux of the problem.

As the diameter of the roll increases, the  torque at the clutch must be increased  proportionately to maintain a constant tension profile in the web. As the torque and roll diameter increase, the slip speed of the clutch also increases as a result of diameter increase … ”

Read the entire article here

Product Spotlight: Micro Rotary Union 

Micro Rotary Union

The Montalvo Micro Rotary Union (MRU) is a mechanical rotating device that allows the transfer of air to and from rotating equipment. It is used in machinery that requires a constant air flow during rotation and can operate at speeds of up to 7000 RPM with a maximum air pressure of 75 psi.

The small size is ideal for use in applications with limited space. The MRU uses micro precision instrument bearings and a carbon seal. The shaft is made of rugged stainless steel.

Visit the MRU product page for more detailed information, datasheets, drawings, and more.

In This Issue:
PFFC Stops by to see Montalvo’s latest produces at ICE USA 2013
Start Superior

PFFC Explores Montalvo’s Newest Products at ICE USA 

Yolanda Simonsis stopped by to check out our newest products at the ICE USA show last week. Check out the video to watch our interview about the new i4, RF load cell and X-series of load cells.

Start with Superior load cells. Finish with Superior product quality. 

Superior tension control starts with a superior tension signal. A superior signal comes from load cells with superior components. Montalvo load cells are designed and manufactured to produce a consistent, repeatable, superior tension signal.

Our load cell overview page shows you exactly what it means when we say we only manufacture load cells that are industry leaders in accuracy, sensitivity, and performance.

View all load cells

In This Issue:
Montalvo attending ICE USA 2013 as a premier exhibitor – Booth #511

Montalvo attending ICE USA 2013 as a premier exhibitor – Booth #511

The International Converting Exhibition returns to Orlando, FL April 9-11. Montalvo will be unveiling a variety of new products and live
product demonstrations as one the show’s premier exhibitors. We are excited to be showcasing our newest tension control products and technology with fully interactive demos.

Interactive Demonstrations Include:

• Range Expansion with the P-3000HD – expand the capabilities of your machine!
• Superior Load Cell Sensitivity, Resolution, and Repeatability with ES Series Load Cells
• Open Loop/Diameter based tension control with the U4 Tension Controller and US4 Ultrasonic Sensor
• Tension Indication with the new re-designed i4
• Easy tension controller installation, set-up and operation with the S4 Tension Controller.
• …and more

New Products Include:

• i4 Tension Indicator – smaller, sleeker and the perfect combination of performance, functionality and convenience!
• “RF” Load Cell – Ideal for filaments, wires, threads and cables like fiber optic, carbon fiber or gold wire the new RF Series of load cells gives you precise, accurate, and highly sensitive tension signals.
• “N1” Load Cell – The newest addition to our N Series of Cantilever style load cells, the N1 is a completely customizable unit meeting the precise needs of your application.
• “R1” Load Cell – A cousin to the N1 and part of the R Series of load cells for applications utilizing pulleys. Like the N1, the R1 allows for complete customization to meet your applications needs, but at a lower cost.

Other products on display include the

F Series compact/pancake style load cells,

U Series under pillow block load cells, and our entire lineup of tension control brakes and clutches

You can find us at Booth #511 at ICE USA! We hope to see you at either show and look forward to talking with you more about your current and future tension control needs!

In This Issue:
Revisited: Precise Web Control’s Role in Film Converting
In Brief: Flexo Tension Control

Revisited: Precise Web Control’s Role in Film Converting

Excerpt: “In today’s competitive marketplace, manufacturers and converters are under pressure to satisfy varied and often conflicting demands. In a time when customers carry little in the way of inventory, manufacturers and converters must strive to meet customer on-time delivery demands. At the same time customers look to their suppliers for improved performance at lower cost. If these requirements were not in themselves a challenge – converters must process materials that can be both varied and potentially problematic. All of these requirements must be met in order to remain competitive.

Unlike materials such as paper, glass and foils; plastic and plastic film materials are relatively new materials. For the brand owner, the retailer and others, plastic films provide many advantages, allowing manufacturers and converters to address a varied range of requirements. For example, thinner gauged films reduce material costs, while different multi-layer structures, developed using co-extrusion, extrusion lamination, adhesive lamination and coating provide a range of performance properties, such as barriers against aroma, light, fats, gas and moisture…”

Read the entire article here

In Brief: Flexo Tension Control

Excerpt: “A key area of development, which has impacted all processes has been the advances made in tension control systems.= The ability to measure and control has and will continue to be fundamental to the success of all web-based converting operations, including flexography. Without the ability to measure and control web tension accurately, numerous process inconsistencies will arise.

Poor tension control through inappropriate or outdated tension control systems greatly affects the ability to produce quality product. The costly and often extensible nature of many materials combined with today’s emphasis on speed-to-market has meant that converters can no longer afford to tolerate suspect tension\ control systems. They demand systems that are highly responsive in order to minimize make-ready, maximize uptime and achieve optimum output on a wide range of materials with minimal waste.

Tension control impacts many areas of an operation, some obvious, so not as obvious. For example, a registration control system is used to automatically adjust the image printed by one station relative to the images printed on the other press stations without continual operator interference. However, a limit to the system’s ability to regulate register is imposed if tension is not properly regulated.”

Read the full article here

In This Issue:
In Brief: Coating & Laminating Tension Control
Product Spotlight: X-3400HD All-in-One Tension Controller

In Brief: Coating & Laminating Tension Control

Excerpt: “The proper control of web tension is especially important for maintaining consistent and high quality in coating and laminating processes. For example, in coating, variation in web tension can lead directly to variations in coat weight and may cause spreading problems leading to carry over onto rollers. Even variations across the web width can cause quality problems with Meyer bar, air knife, or reverse roller coating systems. A display of right, left, or total tension can be invaluable in counteracting this.

In the case of laminating lines it is not only the absolute tensions that are important, but also the relative tensions of one laminated material to another. These must be correctly related to the stress/strain characteristics of the material if subsequent distortion due to differential contraction is to be avoided.”

Read the entire Article here

Product Spotlight: X-3400HD All-in-One Tension Controller

Combining the best of analog and digital capabilities with a range of tension control features makes the X-3400HD one the most advanced web tension controllers in the industry.

The X-3400HD gives you greater control while providing specific Unwind, Intermediate Zone, and Rewind features to ensure your process is as productive & profitable as possible.

Benefits Include:

• Process Versatility
• The X-3400HD Tension Controller can be configured for any of your process zones: Unwind, Intermediate, or Rewind.
• Variable Wrap Angle Technology
• Montalvo exclusive Variable Wrap Angle Technology eliminates the need to isolate the tension sensing roll and allows for roll contact to be made to only one side of your web. Learn more here
• Unwind, Intermediate, and Rewind Functionality
• Inertia Compensation: minimizes tension variations on rewind during start or stop
• Web Break Detection: stops machine should a break occur
• Taper: builds excellent rolls & eliminates telescoping and crush cores
• Splice: maintains tension for more successful splices
• Soft-Start: eliminates shocks to the web on startup
• Anti-Coast: prevents web tension from dropping on stop
• Analog & Digital Hybrid
  • The speed of analog combined with the functionality of digital; the X-3400HD Tension Controller gets your material to the desired tension, and makes tension corrections faster than any other controller. Simple to Program, Highly Responsive!
• …and more

For a full list of features and benefits, datasheets, and more, visit the X-3400HD Product page