What does the machine do?
The technology behind a USAR involves several mechanical, electrical, and software control components that work together to efficiently slit and rewind large rolls of material, print QR codes and digital embellishments, and do a variety of finishing solutions for ensuring efficient and aesthetically excellent packaging and labels.

Can you explain in detail?
The process begins with the unwinding of a large master roll. The unwinding mechanism ensures controlled tension as the material feeds into the machine. Tension control prevents material distortion, wrinkles, or tears during the slitting and rewinding process.

The slitting mechanism consists of multiple circular blades or rotary knives that are adjustable in terms of their positioning and depth. These blades are responsible for cutting the wide roll into narrower strips according to the desired width specifications. The slitting process requires precise alignment and control to ensure clean and accurate cuts. We offer all three types of slitting, including scissors, razors, and crush cuts.
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The rewinding mechanism involves winding the slit material onto separate cores to create smaller rolls. This mechanism includes a winding shaft, chucks, and tension control to ensure the material is wound uniformly and without wrinkles. Some machines also offer differential winding capabilities, which adjust the speed of the winding shafts to control tension variations between layers of material.

What is the edge guiding system?
This system uses sensors to detect the edges of the material and make real-time adjustments to ensure that the slitting and rewinding are done accurately along the desired lines. This is especially important for materials with uneven edges or those that tend to shift. For pre-printed rolls, a printed line guide can also be installed as an option to ensure that the finishing process follows the print and not just the edge of the web.

Tell us about the tension control systems.
Throughout the slitting and rewinding process, maintaining consistent tension in the material is crucial. Tension control systems involve various components, such as sensors, rollers, and feedback loops to ensure that the material is neither too loose nor too tight during winding. This prevents material defects and maintains product quality. Our ability to handle from 12-micron films to 600-micron boards, including a range of difficult materials including lamitubes, blister aluminium, etc proves the robustness of the software and the drive technologies.

What are the other aspects of the machine? 
Modern USAR technologies often incorporate advanced control systems. These systems may include PLCs or other computer-based controllers that allow operators to input parameters such as the desired width, the number of rolls, tension settings, and more. Automation can improve accuracy, consistency, and efficiency.

The HMI is the user interface through which operators interact with the machine. It could be a touchscreen panel that displays information about the machine’s status, settings, and any alarms. Operators can use the HMI to input commands and monitor the ongoing process.

Safety mechanisms are integrated into the machine to prevent accidents and ensure operator safety. These features might include emergency stop buttons, safety guards, and sensors that detect abnormalities in the process.

How suitable is this product in an extremely price-sensitive market like India?
Our product is able to offer a European level of equipment at a price point which is much more attractive. Our quality is much higher than a similar product made in China. In addition, we have local sales support in most of the markets we work in and ensure that the equipment uptime is the highest compared to our competitors.

When was it launched?
The series was initially launched in 2014. Many upgrades and variants are added each year.

Who is it aimed at?
Packaging converters and label printers.

What is your worldwide customer base for the product?
We have installed more than 200 machines globally with more than 120 machines in India. Leading customers in India include UFlex, Aurobindo Pharma, Pragati Pack, Excel Pack, Mudrika Labels, Skypack, among others.

What are the USPs of the product?
Since each line is customised for a converter, he can choose the options that he wants and also since the system is modular, it can be upgraded to have additional features and options to meet the changing needs of the market.

What are the unique characteristics of the product?
Printing of variable QR codes (including large codes for payment solutions), printing of holographic and metallic QR codes; slitting and finishing of special material, including blister and lamitubes, and die-cutting and finishing of IML labels.

What are the unique characteristics of the product?
Printing of variable QR codes (including large codes for payment solutions), printing of holographic and metallic QR codes; slitting and finishing of special material, including blister and lamitubes, and die-cutting and finishing of IML labels.

How about productivity?
All our solutions are tailored to meet the highest levels of productivity and also provide the correct price-performance ratio for the markets in which we operate. Our tax stamp solutions are market leaders across the globe with installations in more than 10 countries and over 30 billion stamps being produced annually on equipment supplied by us.

How easy is it to use?
All our equipment is ergonomic and designed for the least operator fatigue. Our intuitive HMIs are language-agnostic and very easy to operate.

What service and support are on offer?
We have more than 40 service engineers globally offering service support to the equipment that we sell. In addition to on-site and remote service, we offer a host of attractive AMC packages to ensure the highest quality of care for your equipment to enable a longer life as well as the highest uptimes.

Technical Specifications

• All modules are available in web widths of 350-, 450-, 550-, 650-mm
• Inside and outside winding
• Efficient web tension control
• Speed up to 300-m/min
• Choice of rewind mandrel from 1-, 1.5-, 2-, 3-, 6-, 10- and 12-inches.
• Automatic stop of complete roll: at diameter: at label counter or meter count
• Adjustable splicing table with pneumatic clamps for removal of waste product
• Maximum rewind up to 1000-mm in single rewind mode and 450-mm in dual rewind
• 25-, 38-, 76-mm unwind mandrel with servo-driven or pneumatic brake tension control, adapters for 6- or 152-mm cores as well
• Electronic web guidance with ultrasonic sensor suitable for opaque and clear substrates