Abstract: Apparatuses and methods of forming discrete stacks of a plurality of zig-zag folded panels are provided. The apparatus and methods include defining a sheet to form all of the panels of the discrete stack of panels. The sheet may be defined by cutting the sheet from the web prior to folding the web into the interconnected panels for each sheet. The sheet may be defined by forming a separation line prior to folding the web into the interconnected panels for each sheet and then separating the sheet from the web of material at the separation line after the web of material is folded into the interconnected panels.

Abstract: A bulk pack napkin separator and method utilize various combinations of simultaneous compression of several bulk packs and various forms of bulk pack accumulators for improving speed and functionality of the separator.

Abstract: A log accumulator comprising a plurality of buckets, a feed arrangement and a transport system and methods are provided. The feed arrangement loads logs onto the buckets. The transport system transports the buckets past the feed arrangement for loading of the buckets. The transport system and the feed arrangement are configured to maintain the feed arrangement in a fixed relative position with one of the buckets for an extended period of time while the feed arrangement loads the one of the buckets. The accumulator may include an unload arrangement that operates to unload logs in substantially the same manner as the feed arrangement.

Abstract: A folding apparatus and method are provided for producing a single-folded pattern of interfolded sheets from a single web of material, through the use of a sheet cutting and directing arrangement having a sheet crossover arrangement. Some embodiments are operable in a variety of modes, with one or two webs of material, to produce either single-fold or multi-fold patterns of interfolded sheets. Some embodiments include a sheet cutting arrangement inside of the sheet cutting and directing arrangement for selectively producing sheets of various lengths.

Abstract: An interfolding apparatus and method, utilize, first and second sheet-cutting-and-overlapping arrangements and an interfolding arrangement simultaneously mounted and operatively interconnected in a common frame, for alternatively selectively forming a first or a second interfolded pattern having a given folded width, without replacement of components of the interfolding apparatus. The first interfolded pattern is formed from a first stream of overlapped sheets of a first length cut from a web of sheet material fed along a first path extending through the first sheet-cutting-and-overlapping arrangement to the interfolding arrangement. The second interfolded pattern is formed from a stream of overlapped sheets of a second length cut from the web of sheet material fed along a second path extending through the second sheet-cutting-and-overlapping arrangement to the interfolding arrangement.

Abstract: The invention provides a method and apparatus for separating a stack of folded sheets by inserting a first, second, third and fourth count fingers into four successive openings in the stack, and separating the stack between the second and third count fingers. Where separation is carried out after a desired number of folded sheets have passed the third count finger, a completed pack having the desired number of sheets may be formed downstream from the third count finger. The count fingers may be operatively mounted in count finger cassettes.

Abstract: The invention provides a method and apparatus for separating a stack of folded sheets by inserting a first, second, third and fourth count fingers into four successive openings in the stack, and separating the stack between the second and third count fingers. Where separation is carried out after a desired number of folded sheets have passed the third count finger, a completed pack having the desired number of sheets may be formed downstream from the third count finger. The count fingers may be operatively mounted in count finger cassettes.

Abstract: A method and apparatus are provided, for forming a stack of interfolded sheets of porous material including a leading panel having a partial-panel width joined along a fold line to a trailing panel having a full-panel width, by controlling the position of leading edges of the sheets both upstream and downstream from the nip between the interfolding rolls of the folding machine with vacuum applied through corresponding vacuum ports disposed in the periphery of the folding rolls at circumferential distances equal to the partial panel length ahead of each gripper and tucker in the direction of rotation. Sufficient suction is applied to hold both the leading edge of the leading panel of a given sheet and an underlying portion of the trailing panel of the immediately preceding sheet against the periphery of one of the other of the rolls downstream from the nip.

Abstract: A splice is made, between a tail end of first web and a lead end of a second web coiled about an unwind axis, by winding a portion of the first web adjacent the tail end of the first web about a splicing roll mounted for rotation about a splice roll axis oriented substantially parallel to the unwind axis, and then joining the tail end to the lead end by compressing an adhesive between an inside surface of the tail end and an outer surface of the second web. Compression of the adhesive is accomplished by urging the splice roll against the coiled second web while the coiled second web is rotating about the unwind axis in an unwind direction and the splicing roll is rolling about the splice roll axis in a direction opposite to the unwind direction.

Abstract: An interfolder separator apparatus and method utilize a pair of count fingers that are movable longitudinally along and transversely to a stream of folded sheets, for temporarily supporting each successive pack formed by the separator and then releasing each successive pack when partly completed to alternating build fingers, so that the operation of separating successive packs from one another is performed separately from the operations of completing the build of each pack and transporting the completed packs to downstream operations. The count fingers may be mounted to pivot about axes that are movable longitudinally along and transversely to the stream of sheets. A first or last panel of the completed pack may also be folded back partly upon itself, after the partly completed pack is released by the count fingers. Some or all of the fingers may be spring loaded and automatically resettable for clearing jams.

Abstract: An interfolder separator apparatus and method utilize a pair of count fingers that are movable longitudinally along and transversely to a stream of folded sheets, for temporarily supporting each successive pack formed by the separator and then releasing each successive pack when partly completed to alternating build fingers, so that the operation of separating successive packs from one another is performed separately from the operations of completing the build of each pack and transporting the completed packs to downstream operations. The count fingers may be mounted to pivot about axes that are movable longitudinally along and transversely to the stream of sheets. A first or last panel of the completed pack may also be folded back partly upon itself, after the partly completed pack is released by the count fingers. Some or all of the fingers may be spring loaded and automatically resettable for clearing jams.

Abstract: A rotating saw clamp for clamping a product roll to be sawn. The rotating log saw clamp includes a first portion disposed for rotation about an axis and a second portion disposed for rotation with the first portion and movable relative to the first portion between an open position and a clamping position. The second portion is rotatable from the clamping position to the open position in rotation of the first and second rotating portions in a common direction.

Abstract: An interfolding apparatus and method, utilize, first and second sheet-cutting-and-overlapping arrangements and an interfolding arrangement simultaneously mounted and operatively interconnected in a common frame, for alternatively selectively forming a first or a second interfolded pattern having a given folded width, without replacement of components of the interfolding apparatus. The first interfolded pattern is formed from a first stream of overlapped sheets of a first length cut from a web of sheet material fed along a first path extending through the first sheet-cutting-and-overlapping arrangement to the interfolding arrangement. The second interfolded pattern is formed from a stream of overlapped sheets of a second length cut from the web of sheet material fed along a second path extending through the second sheet-cutting-and-overlapping arrangement to the interfolding arrangement.

Abstract: A splice is made, between a tail end of first web and a lead end of a second web coiled about an unwind axis, by winding a portion of the first web adjacent the tail end of the first web about a splicing roll mounted for rotation about a splice roll axis oriented substantially parallel to the unwind axis, and then joining the tail end to the lead end by compressing an adhesive between an inside surface of the tail end and an outer surface of the second web. Compression of the adhesive is accomplished by urging the splice roll against the coiled second web while the coiled second web is rotating about the unwind axis in an unwind direction and the splicing roll is rolling about the splice roll axis in a direction opposite to the unwind direction.

Abstract: A method and apparatus are provided for facilitating folding of material fed through a nip between two folding rolls having a tucker on one roll and a corresponding gripper on the other roll, by using a resilient tucker element having a tip that is moveable from a neutral position thereof, through elastic deformation of at least a portion of a body of the tucker element, for directing a portion of the material into the gripper. The resilient tucker element may have a tucker body formed at least partially of elastically resilient material fixedly attached at a proximal end thereof to the other roll. A portion of a distal end of the resilient tucker element may be wedge-like and have vacuum ports extending at least partially into the wedge-like portion, for securing an end of a sheet of material being fed through the nip between the folding rolls.

Abstract: A rotating log saw clamp for clamping a product roll to be sawn. The rotating log saw clamp includes a first portion disposed for rotation about an axis and a second portion disposed for rotation with the first portion and movable relative to the first portion between an open position and a clamping position. The second portion is rotatable from the clamping position to the open position by relative rotation of the first and second rotating portions in a common direction.

Abstract: A flexographic printing apparatus and method utilize a support platform attached to a printer frame and four bearing support carriages attached to the support platform for operatively supporting opposite ends of a plate roll and an anilox roll. One plate roll carriage and one anilox roll carriage are operatively attached to the support platform along each opposite side of the support platform by a common linear guide arrangement. The plate roll carriages are positioned along the linear guide arrangements by two plate roll linear positioners operatively attached between the support plate. The anilox carriages are positioned along the linear guide arrangements with respect to the plate roll carriages by a pair of anilox roll linear positioners operatively attached between the plate roll and anilox roll carriages. The support platform is also transversely movable with respect to the printer frame for lateral registration.

Abstract: An interfolding apparatus and method, utilize, first and second sheet-cutting-and-overlapping arrangements and an interfolding arrangement simultaneously mounted and operatively interconnected in a common frame, for alternatively selectively forming a first or a second interfolded pattern having a given folded width, without replacement of components of the interfolding apparatus. The first interfolded pattern is formed from a first stream of overlapped sheets of a first length cut from a web of sheet material fed along a first path extending through the first sheet-cutting-and-overlapping arrangement to the interfolding arrangement. The second interfolded pattern is formed from a stream of overlapped sheets of a second length cut from the web of sheet material fed along a second path extending through the second sheet-cutting-and-overlapping arrangement to the interfolding arrangement.

Abstract: An interfolding apparatus and method, utilize, first and second sheet-cutting-and-overlapping arrangements and an interfolding arrangement simultaneously mounted and operatively interconnected in a common frame, for alternatively selectively forming a first or a second interfolded pattern having a given folded width, without replacement of components of the interfolding apparatus. The first interfolded pattern is formed from a first stream of overlapped sheets of a first length cut from a web of sheet material fed along a first path extending through the first sheet-cutting-and-overlapping arrangement to the interfolding arrangement. The second interfolded pattern is formed from a stream of overlapped sheets of a second length cut from the web of sheet material fed along a second path extending through the second sheet-cutting-and-overlapping arrangement to the interfolding arrangement.

Abstract: An apparatus and method for creating stacks of sheets. In some embodiments, the sheets separated are those in or issuing from a starwheel assembly. The present invention includes a first separator finger that is inserted between two adjacent sheets to separate first and second sheets. The first separator finger retains the first sheet upstream to begin a first stack upstream of the first separator finger and allows the second sheet to complete another stack downstream of the first separator finger. In some embodiments, the first separator finger is inserted between the two adjacent sheets in a closed position and, after the first separator finger is inserted, the first separator finger moves to an open position to create a gap between the first and second stacks.