Specialty unwind shaftless winders and rewinders
Our Products Model EP Shaftless Unwind Model EP Junior Shaftless Unwind Model DU Dual Roll Shaftless Unwind Cast Grip Core Chucks Specialty Unwind & Rewind Configurations Spindle Driven Unwinds Surface Driven Unwinds Motorized Aisle Loading Mid-Process Rewinds Flexo Press Upgrades Corrugated Unwind Model XH Unwind Ancillary Equipment Dancer Units Tension control Edge guide

Specialty Unwind & Rewind Configurations

(click on thumbnail to enlarge)

Spindle-Driven Unwinds

Spindle driven unwinds - Click to enlarge
Spindle-Driven Unwind
A spindle drive can be implemented as an alternative to traditional braking or when the user needs to accelerate a roll faster than could be done by pulling on the web alone. A good example of this would be films that are highly extensible. Braking can be regenerative.

Surface Driven Unwinds

Surface driven unwinds- Click to enlarge
Spindle-Driven Unwind
Surface driven unwinds- Click to enlarge
Spindle-Driven Unwind
Surface driven unwinds- Click to enlarge
Spindle-Driven Unwind
 

The new surface-driven unwind boasts all of the proven features of the model EP Shaftless unwind. The stand is shaftless and roll-lifting and can be configured for small rolls or up to 10,000-lb. rolls. The shaftless roll-lifting design eliminates shaft-related back injuries and speeds roll changes significantly, allowing for higher daily production.

The model GB surface-drive is integrated with the base stand to provide a complete and compact surface-driven solution. A surface drive is ideal for light materials which are extensible or too light to be accelerated at the desired rate by traditional unwinding methods. Dancer and load cell feedback is available.

Motorized Aisle Loading

Motorized aisle loading - Click to enlarge
Motorized Aisle Loading
Motorized aisle loading - Click to enlarge
Motorized Aisle Loading
This is a popular option when multiple stands are to be used in line or when spaces are too confined to allow ordinary roll loading. The photo shown is of a sheeter running simultaneous multiple webs. The option saves floor space by eliminating the need to leave room between stands for roll loading. A printing press which is designed with the mill-roll to be loaded and run underneath the press framework is another example. There is no room under the press for staging and loading the large diameter rolls converters would like to run. The roll is staged to the side of the press and the unwind travels out from under the press to accept the new roll.

Mid Process Rewinds

Mid Process Rewind - Click to enlarge
Mid Process Rewinds
The same framework that is used for our unwinds can be used for a shaftless rewind. The flexibility of roll width, diameter and core size a shaftless unwind offers is available on the rewind end using this method. The bolt-on flange for core chucks can accommodate traditional shaftless core chucks or a special adapter that allows the use of a differential rewind shaft should the converter wish to rewind multiple cuts on separate cores. We call this offering mid-process since we see it being used at middle stages of manufacture. Product may have met one stage of progression but may need to be stored or moved to another area of a plant before it can go on to the final process. It is rewound at this "mid-process stage".

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Flexo Press Upgrades

Greatly increase the amount of product you can produce with your existing  press. Shaftless operation speeds the loading and unloading of rolls to get your press back up and making product. This setup eliminates shaft related costs and injuries. Unwinds are braked and rewinds are fitted with a custom sized motor/ gearbox package. Wound rolls are simply set down onto the floor, pallet or roll cart. Unwind rolls are lifted directly from the floor.

Staged rolls keep your machinery from being dependant on other equipment for roll changes. If your press speed is the bottleneck and safety is a concern then this system is an excellent solution

Roll to roll printing is ideal for this setup. This is where the shaftless design can yield the absolute highest production for your press.

Many presses will benefit from utilizing a dancer system on the in-feed. Tension spikes are smoothed allowing you to run higher speeds while maintaining print registration.

Lines requiring slitting prior to rewind may be accommodated in some cases through the use of a special shaft accommodation adapter, a differential rewind shaft and bowed rolls to accomplish the required separation.

Going shaftless is no longer limited to unwinding. Shaftless rewinding is suitable for many substrates!

Braking/ Motor / Gearbox packages are custom configured. Core chucks vary in style and size depending upon the application.

Load cell or dancer tension control available.

Edge guiding available for unwind and rewind.

Custom loading / unloading configurations available for confined spaces.


Model EP shaftless unwindd benefits
Flexo Press Upgrades

Model EP Jr. Shaftless Rewind and Unwind Benefits:
Minimize down time by getting your press back up and running FAST.
Increase production with faster, one person roll changes on both ends of the press.

Extremely reliable design is simple to operate and maintain.
Eliminate shaft handling, shaft maintenace and shaft related injuries.

For rewind, set completed rolls directly onto your floor. Save time with quick rewind end changeover. For unwind have rolls staged and ready to load. Lift directly from the floor.

Model EP JR shaftless rewind benefits
Flexo Press Upgrades

Model EP Jr. Shaftless Rewind and Unwind Specifications:

Handles rolls up to 3000 lbs.
Maximum Diameters of 36" 48" 60" 66" and 72".
Widths up to 36".

Rewind Spindle Drives are sized for your specific application.
Tension control systems, edge guide systems, and other related accesories available.
Unwind braking custom configured.

Larger models are available for greater weights, widths, and diameters.

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Corrugated Unwind

Corrugated Unwind- dual position shaftless unwind
Corrugated Unwind

The model DU Dual position shaftless unwind is the newest addition to the Powell Engineering Inc. product line. The combination of dual roll capacity, shaftless floor pickup and side loading by cart are ideal for multiple web and confined spaces. The model DU is ideal for corrugator line new installations and upgrades. Run multiple rolls simultaneously or have rolls waiting and ready to go. The machine is made in the tradition of Powell Engineering Inc.'s other equipment in that it is extremely robust and designed to be reliable through simplicity of design. The ability to achieve low diameter pickup makes the loading or unloading of short run butt rolls a simple task. A variety of brakes and core chucks are available. The standard corrugating configuration utilizes compact design brakes and Double E brand DF-2000 torque chucks.

An overhead carry over structure is available to transport the web downstream which may be configured with a skew roll, dancer or load cells for tension control as well as web guiding.

Side loading via roll carts minimizes roll handling and makes the job of keeping your line up and running an easy one. Carts may be configured as simple single position side loading units or a complete multiple position turntable and transfer system may be utilized.

Upgrade your machines today with the reasonably priced model DU from Powell Engineering Inc.

Model XH Unwind

Model XH shaftless unwind
Model XH Unwind

The Model XH shaftless unwind is capable of running rolls weighing up to 20,000 pounds. The same options are available as are for the model EP.

This picture shows a special forced air cooled brake set-up. The customer runs this machine at high speed and tension so we need to dissipate a lot of heat.

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