Zero speed splicing for hot melt coating line
Zero-speed splicing is a sophisticated method for changing rolls of material on a continuous hot melt coating line without stopping the production process. Also known as zero-tail or butt splicing, this technology prevents the large amount of waste and downtime caused by traditional flying splices. The system uses a festoon: a tower of rollers that can store a significant length of material being pulled from a moving roll. When a roll of material runs low, the line seamlessly switches to the stored supply in the festoon. While the line continues running at full speed, the machine stops the empty roll, aligns a new, full roll, and joins the new leading edge directly to the trailing edge of the old one with tape, cutting off no material, before restarting the new roll.
The technical benefits of zero-speed splicing are dramatic for production lines. The splice itself is of extremely high quality, with the web walking less than 1.6mm (1/16-inch) as it passes through the machine, causing minimal to no disruption to the coating process. Because the splice has no overlapping "tail," it does not disturb the adhesive "curtain" on an extrusion coater or cause the web to stick to the chill roll. The result is that no material is thrown away during a splice, directly increasing production yield. Many extrusion coating line operators report that a large percentage of sheet breaks occur during a traditional splice; a zero-speed splicer is proven to operate with far fewer breaks, dramatically increasing machine reliability.
Hot Melt Coating Machine - Hot Melt Adhesive Coating Machine
Automation is a key feature of a modern zero-speed splicing system. A single operator can manage the entire roll preparation and loading process thanks to automated loading and unloading assistance. The loading sequence for a standard operator takes only 3 to 4 minutes. The system then uses sensors and a precise control system to manage the festoon, maintain perfect tension, and execute the splice at the exact moment the old roll is depleted. This high level of automation reduces manual labor tasks and removes the potential for human error from the splicing process, leading to a safer, more predictable, and more profitable operation.
Zero-speed splicing is applicable to a vast range of materials, including paper, paperboard, tissue, film, nonwovens, and flexible packaging substrates. It can be integrated into both the unwind and rewind sections of a coating line. At the unwind, it ensures a continuous feed of raw material; at the rewind, it allows for the continuous take-up of finished rolls, enabling the entire line to be fully automated. The technology is even more valuable when processing delicate, expensive, or difficult-to-splice materials, where the risk of web breaks is highest.
The value proposition for zero-speed splicing is centered on increased efficiency and reduced waste. A line integrated with a zero-speed splicer can run at speeds of 800 mpm (meters per minute) or higher without any interruption. The elimination of waste from overlapping tails—and the resulting need to trim that scrap—directly improves the bottom line by saving valuable raw materials. While the initial investment in a zero-speed splicing system is higher than a standard manual or automatic flying splice, the reduction in scrap, increase in good throughput, and reduction in sheet breaks quickly lead to a strong return on investment for high-volume producers.
When selecting a zero-speed splicing system for a hot melt coating line, it is essential to ensure compatibility with your specific substrate width, material properties, and maximum line speed. The festoon must be large enough to provide sufficient material storage, and the control system must integrate seamlessly with the line's main drive. With proper integration, zero-speed splicing technology can be the centerpiece of a 24/7 coating operation, maximizing asset utilization and delivering consistent, high-quality output.
