Foam Roll to Sheet Cutting Machine 1200 mm – Foam and Base Release Pasting With Sheet Cutting

It is a wide web paste and sheet machine with two unwinds. The foam unwinding unit takes a roll of up to 1000 mm diameter on a 3 inch manual shaft with mechanical brake tension control. The base release unwinding unit takes a liner roll of up to 250 mm diameter, also on a 3 inch manual shaft with mechanical brake. The two webs meet at a sandwich type roller system that presses the foam on to the base release.

From there, a rotary blade attachment with bottom support and four blades slits the laminate, a Schneider servo based nip roll control pulls the web, and cutting length control with servo feed sets the sheet size. A rodless pneumatic cylinder performs the sheet cut. The digital controller manages cut set, sheet set and total stroke count from the touch screen HMI with PLC. For roll to roll output, a rewinding unit takes up to 1000 mm diameter with mechanical clutch tension control. The maximum paper width is 1200 mm.

Two Unwinds for Foam and Base Release

The foam roll and the release liner roll each have their own unwinding unit with 3 inch manual shaft and mechanical brake tension control, so each web is held at the tension it needs before pasting.

Sandwich Type Roller Pasting System

The foam and the base release are joined through a sandwich type roller system. The rollers press the two webs together evenly across the full 1200 mm width, giving a flat, bubble free laminate.

Servo Based Nip Roll Control (Schneider)

The nip roll that pulls the laminate is servo controlled with Schneider components, so the web advances by the same amount on every cycle and the sheet length stays constant.

Cutting Length Control With Servo Feed

The cut length is set from the HMI and controlled by the servo feed, from a minimum of 6 inches to a maximum of 40 inches.

Touch Screen HMI With PLC

All settings, cut set, sheet set and the total stroke counter are on a touch screen HMI backed by a PLC controller. Job settings are entered once and repeated exactly.

Rodless Pneumatic Sheet Cutting

The sheet cut is performed by a rodless pneumatic cylinder, which gives a straight, clean cut across the foam laminate without a heavy mechanical press.

Rotary Blade Slitting With Bottom Support

A rotary blade attachment with bottom support and four blades slits the laminate inline, so sheets can be produced in narrower widths from the 1200 mm web.

Rewinding Unit for Roll to Roll Work

When the laminate is wanted in roll form, the rewinding unit takes up to 1000 mm diameter with mechanical clutch tension control.

The operator loads the foam roll on the foam unwind and the release liner on the base release unwind, sets the mechanical brakes for the tension each material needs and threads both webs into the sandwich roller system. The pasted laminate is threaded through the slitting attachment, the servo nip roll and the cutting unit. On the HMI the operator enters the cutting length, the cut set and the sheet set.

When the cycle starts, the servo nip roll advances the laminate by exactly the set length, the rodless pneumatic cylinder makes the cut and the sheet is delivered. The controller counts every stroke and completes the set. If the job is roll to roll, the cutting unit is left idle and the laminate winds on the rewinding unit under mechanical clutch tension. Because the pasting, slitting and cutting happen in one pass, the foam is handled once and the sheets come out square and to length.

• Foam tape and gasket sheets – laminating foam to release liner and cutting sheets for die cutting.
• Cushioning and packaging pads – foam sheets in set lengths from rolls.
• Insulation and sealing foam – lined foam sheets for construction and HVAC components.
• Automotive foam parts – lined foam sheets ready for die cutting into parts.
• Paper and board sheeting – with the pasting stage idle, the machine also works as a 1200 mm roll to sheet cutter.

The machine is designed for foam rolls up to 1200 mm wide, pasted to a base release liner, and for the lined foam laminate that results. It can also run paper and similar web materials up to 1200 mm wide as a plain roll to sheet cutter. Foam thickness, density and adhesive type all affect pasting and cutting, so send RK samples of your foam and liner before the machine is configured.

• Offline Roll to Sheet Cutting Machine 1300 mmwide web paper sheeter with 4 kW servo feed, print mark scanner and auto step-down table.
• Offline Roll to Sheet Cutting Machine 320 mmnarrow web label roll to sheet cutter with a 30 mm minimum cut.
• Foam Die Cutting Machinefor die cutting the lined foam sheets into finished parts.

RK Label Printing Machinery Pvt. Ltd. has manufactured label printing and converting machinery in Ahmedabad, Gujarat since 1995, across three manufacturing units, for customers in 23+ countries. The foam roll to sheet machine combines RK's web handling, servo feeding and pneumatic cutting in a format built for foam converters, and RK also supplies the foam die cutting machine that follows it. One manufacturer designs, builds and services the whole foam converting line.

• Material: foam with a release liner points to this machine; plain paper reels may be better served by the 1300 mm or 320 mm sheeters.
• Web width: up to 1200 mm here.
• Roll sizes: foam rolls up to 1000 mm diameter and liner rolls up to 250 mm diameter on 3 inch shafts.
• Sheet lengths: 6 inches to 40 inches. Confirm your longest and shortest sheets.
• Roll or sheet output: the rewinding unit lets you deliver the laminate in rolls when a customer wants it that way.
• Slit widths: four rotary blades are supplied; tell RK the widths you need.

The price of the RK Foam Roll to Sheet Cutting Machine depends on the configuration supplied, including blade sets and any options for your foam, liner and sheet sizes. RK quotes ex-works Ahmedabad with GST at 18% applicable. Engineer travel and stay for installation and training at your site are borne by the customer. Share your foam and liner specifications, roll sizes and sheet formats with RK, and the engineering team will confirm the build and quote against it.