Abstract: An interfolding apparatus including a knife roll rotatable about an axis and operable to cut successive sheets from a stream of web material issuing from a source in a downstream direction. A folding roll is positioned downstream of the knife roll and is rotatable in a first direction at a first roll speed. An additional roll is disposed adjacent to the folding roll and is rotatable about an axis in a second direction at a second roll speed. The additional roll is operable to receive the successive sheets and release the successive sheets in the downstream direction toward the folding roll. The folding roll and the additional roll define a nip therebetween, the successive sheets passing through the nip. The first roll speed of the folding roll is different from the second roll speed of the additional roll, the difference in speed between the folding roll and the additional roll operable to overlap adjacent portions of the successive sheets onto the folding roll.

Abstract: An apparatus and method for moving stacks of product discharged from a stacking device. The apparatus includes a first conveyor movable at a first speed and a second conveyor movable at a second speed. The first conveyor includes an upstream end adjacent to the stacking device. The first conveyor is positioned to receive product from the stacking device. The second conveyor includes an upstream end adjacent to the stacking device. The second conveyor is positioned to receive product from the stacking device. The running speed of the first conveyor is faster than the running speed of the second conveyor to move stacks of product on the first conveyor away from the stacking device at a faster speed than stacks of product on the second conveyor.

Abstract: A method and apparatus for wrapping stacks of web product with wrap web material supplied from a supply roll. The apparatus includes a conveyor for supporting and moving the stacks to be wrapped along a conveying path, a drive assembly operable to receive wrap material from the supply roll and positively feed the wrap material to the conveying path, and a wrapping assembly for manipulating the wrap material around the stack. The method includes supporting and moving the stacks to be wrapped along a conveying path, rotating a cutting roll, clean cutting the wrap material received from the supply roll to separate a wrap sheet from the wrap material, defining a trailing edge of the wrap sheet, delivering the trailing edge to the conveying path after the wrap sheet is separated from the wrap material, and manipulating the wrap sheet around the stack.

Abstract: A starwheel feed apparatus and method for feeding and guiding sheets of a web material into a starwheel assembly. In some embodiments, a feeding conveyor is movable to convey sheets at a first velocity toward the starwheel, and a guiding conveyor is located adjacent the starwheel and has a conveying surface movable at a velocity less than the first velocity. In other embodiments, other relative speeds of the guiding and feeding conveyors are employed. In some embodiments, a feeding conveyor feeds sheets into slots of a starwheel, and a guiding conveyor located adjacent the starwheel has a conveying surface to guide trailing edges of the sheets along a length of the conveying surface as the sheets enter the slots.

Abstract: A log packaging apparatus for packaging logs using a turret or a shuttle. The turret or shuttle can be used in conjunction with a wrap conveyor. The turret system can include a rotatable turret with at least one clamp movable into different positions in the apparatus, a log station at which logs are received, and a log ejector for ejecting logs from the log station into clamps of the turret. Logs can be ejected from the log station, through wrap material, and into the turret clamps. In other embodiments, a wrap conveyor inserts wrap material between a shuttle and a log station at which logs are received. Logs in such embodiments can pass from the log station to the shuttle through the wrap material.

Abstract: A rewinder having a first winding roll that transports and supports the web, and a second winding roll located a distance from the first winding roll to define a nip therebetween. The rewinder also include at least one core support plate that is curved for receiving and guiding cores adjacent the first winding roll, a contact finger located adjacent the first winding roll, and a web separation bar adjacent the first winding roll and movable into pressing relationship with the web to press the web against the contact finger to separate the web. In some embodiments, the contact finger is recessed within the first winding roll such that the web separation bar presses the web only against the contact finger to separate the web.

Abstract: A method and apparatus for folding over a portion of at least one top sheet of a stack of interfolded sheets. The foldover apparatus includes a conveyor adapted to move the stack in the downstream direction, a vacuum assembly adapted to separate at least a portion of the at least one top sheet from the remainder of the stack, and a forming plow to fold over the portion of the at least one top sheet. The method includes moving the stack of sheets downstream along a path, separating the portion of the at least one top sheet from the remaining portion of the stack of interfolded sheets, moving the portion of the at least one top sheet adjacent a forming plow, moving the portion of the at least one top sheet along the folding plow, and folding over the portion of the at least one top sheet.

Abstract: In some embodiments of the present invention, a method and apparatus for folding sheets are disclosed in which single transverse folds are created by vacuum rolls in one operational mode and double transverse folds are created by vacuum rolls in another operational mode. The folder can have a low profile in which the axes of various elements and assemblies in the folder are located within height ranges relative to the height of a folding roll axis in the folder.

Abstract: A starwheel feed apparatus and method for feeding and guiding sheets of a web material into a starwheel assembly. In some embodiments, a feeding conveyor is movable to convey sheets at a first velocity toward the starwheel, and a guiding conveyor is located adjacent the starwheel and has a conveying surface movable at a velocity less than the first velocity. In other embodiments, other relative speeds of the guiding and feeding conveyors are employed. In some embodiments, a feeding conveyor feeds sheets into slots of a starwheel, and a guiding conveyor located adjacent the starwheel has a conveying surface to guide trailing edges of the sheets along a length of the conveying surface as the sheets enter the slots.

Abstract: An apparatus and method for applying adhesive in a web converting machine is disclosed. In some embodiments, an adhesive application assembly is used to seal the tail of a rolled product against the rolled product. After being positioned in a location upon a roller, the rolled product is rotated and a sensor detects the location of the tail end, thereby establishing a reference for determining tail length in later operations. When the tail reaches a desired position, the adhesive application assembly applies adhesive to the tail and/or rolled product. In some embodiments, the adhesive assembly includes one or more adhesive sprayers with aperture members, and is self-cleaning. After the adhesive has been applied, the tail is wound upon the rolled product. In some embodiments, an adhesive application assembly is employed to apply adhesive to a core about which sheet material is to be wound.

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 apparatus and method for applying adhesive in a web converting machine is disclosed. In some embodiments, an adhesive application assembly is used to seal the tail of a rolled product against the rolled product. After being positioned in a location upon a roller, the rolled product is rotated and a sensor detects the location of the tail end, thereby establishing a reference for determining tail length in later operations. When the tail reaches a desired position, the adhesive application assembly applies adhesive to the tail and/or rolled product. In some embodiments, the adhesive assembly includes one or more adhesive sprayers with aperture members, and is self-cleaning. After the adhesive has been applied, the tail is wound upon the rolled product. In some embodiments, an adhesive application assembly is employed to apply adhesive to a core about which sheet material is to be wound.

Abstract: Some preferred embodiments of the present invention includes an apparatus and method employed for cutting a rotating log of rolled product into rolls, the apparatus and method utilized for preventing collapse of a longitudinally extending aperture in the log during the cutting process. The present invention includes a mandrel received within the aperture of the log to at least partially support the log and to preferably maintain the integrity of the aperture while the log is being cut by a saw blade. Preferably, the mandrel has at least one recess within which a saw blade can be received during cutting operations upon the log.

Abstract: A fluid valve for controlling fluid flow and/or vacuum to a plurality of ports and fluid lines in a rotating member has a rotary phase plate with a plurality of apertures therein which can be brought into fluid communication with selected ports and fluid lines in the rotating member by rotation of the rotary phase plate to one of at least two rotational positions with respect to the rotating member. Preferably, the fluid valve has at least a rotary union adapter coupling the rotary phase plate to a one-port rotary union or a roll adapter coupling the rotary phase plate to the rotating member. Most preferably, the fluid valve has both such adapters.

Abstract: An apparatus and method for distributing wear over a plurality of elements on a rotating member. In the case of a cutoff or perforation roll, a plurality of retractable cutoff or perforation blades can be actuated to be extended or retracted to selectively cut or perforate a web. To distribute blade wear, extended blades are occasionally retracted while other blades are extended. Where it is desired to continue producing cuts or perforations of a desired length through such blade indexing, the spacing and number of blades before and after indexing are preferably the same. Most preferably, each blade retracted during indexing is replaced by a blade on the same side of and at the same distance from the blade being retracted. To hold the web during web cutting or perforating operations, the roll is preferably provided with vacuum apertures to which is supplied vacuum via vacuum lines, vacuum valves, and a vacuum source, thereby creating suction through the vacuum apertures.

Abstract: A vacuum timing device for applying a vacuum on a roll includes a roll with an axis of rotation, a surface, and a surface longitudinal axis oriented in a direction substantially parallel to the axis of rotation. The device also includes at least one vacuum line running along at least a portion of the length of the roll. The device also includes a plurality of apertures defined in a surface of the roll and in fluid communication with the vacuum line. In order to alleviate angular delay of vacuum propagation, the plurality of apertures is arranged in a line that is skewed with respect to the surface longitudinal axis. Preferably, the plurality of apertures is arranged in a line that is skewed away from the direction of rotation of the roll, thereby substantially eliminating the angular propagation delay as the vacuum roll operates.

Abstract: An apparatus and method for distributing wear over a plurality of elements on a rotating member. In the case of a cutoff or perforation roll, a plurality of retractable cutoff or perforation blades can be actuated to be extended or retracted to selectively cut or perforate a web. To distribute blade wear, extended blades are occasionally retracted while other blades are extended. Where it is desired to continue producing cuts or perforations of a desired length through such blade indexing, the spacing and number of blades before and after indexing are preferably the same. Most preferably, each blade retracted during indexing is replaced by a blade on the same side of and at the same distance from the blade being retracted. To hold the web during web cutting or perforating operations, the roll is preferably provided with vacuum apertures to which is supplied vacuum via vacuum lines, vacuum valves, and a vacuum source, thereby creating suction through the vacuum apertures.

Abstract: An apparatus and method for sealing the tail of a rolled product against the rolled product using a roller and one or more sensors to position the tail for accurate adhesive application upon the tail and/or the log. After being positioned in a location upon a roller, the rolled product is rotated between the roller and a conveyor assembly until a jet blows the unsealed tail against the roller. By further rotating the roller, a sensor detects the location of the tail end, thereby establishing a reference (along with measured roller and conveyor assembly movements) for determining tail length in later operations. Next, the roller is reversed to pass the tail around the roller and preferably to a tail support adjacent to the roller. When the tail reaches a desired position along the tail support, an applicator sensor sends a signal to an adhesive assembly which applies adhesive to the tail and/or to the rolled product.

Abstract: A separator and stacker apparatus and method for separating a completed stack of web product from a stack of product being built thereafter. Preferred embodiments of the present invention utilize a stack building carriage having a forked or slotted floor cooperating with a load finger assembly to discharge the completed product stack from the stack building carriage. The load finger assembly preferably has a set of load fingers which mesh with the carriage floor so that when the load finger assembly is actuated, the load fingers pass substantially unobstructed through the stack building carriage. The load finger assembly and the stack building carriage can therefore pass through their motions independently of one another, permitting the stack building carriage to return to a stack building position without waiting for the load finger assembly to retract.

Abstract: A starwheel feed apparatus and method for feeding and guiding sheets of a web material into a starwheel assembly. In some embodiments, a feeding conveyor is movable to convey sheets at a first velocity toward the starwheel, and a guiding conveyor is located adjacent the starwheel and has a conveying surface movable at a velocity less than the first velocity. In other embodiments, other relative speeds of the guiding and feeding conveyors are employed. In some embodiments, a feeding conveyor feeds sheets into slots of a starwheel, and a guiding conveyor located adjacent the starwheel has a conveying surface to guide trailing edges of the sheets along a length of the conveying surface as the sheets enter the slots.