Solution:

Profile:

Fast-growing, non-woven fabrics and

laminates manufacturer

LaserSpeed® 4000-303L

Consistently ships correct amount

of product to customers

Higher level of accuracy eliminated

waste and customer bill-backs

Lowered the cost of ownership

Reduced product maintenance

Realized faster payback in savings

Results:

Non-woven fabrics manufacturer eliminates product shortage tocustomers and saves money

Non-wovens production line

A fast-growing, manufacturer of non-woven fabrics and laminates

produces a wide variety of end products for its customers, such as air

filters, patient outer wear, adult diapers, and other items. Over the

years, the manufacturer has expanded its production operations

and formed key strategic partnerships with prominent raw material

suppliers. The manufacturer was also experiencing pressure from

the market, its partners, and the competition to produce higher-

quality non-woven products faster, more accurately, and more

cost effectively.

Application: Length Measurementat Slitter/Rewinder

Industry: Non-Woven FabricsManufacturing

The non-woven fabrics manufacturer received complaints

from an important customer that it was being shorted on

its delivered laminated products. The company used

mechanical wheel encoders at its rewind/slitter station on

the lamination line. The mechanical encoders measured the

length of product as it was being slitted and rewound onto a

roll. On a typical production day, the manufacturer would run

10 rolls a day. Depending on the laminated product produced

on a particular day, rolls lengths would vary: 110 yards rolls or

500 yards. Processing speeds ranged up to 300 ft/min. The

cutting configuration on the slitter differed from job to job

A strategic partner to the manufacturer recommended that it

look into non-contact methods for measuring the true length

of the product. The manufacturer contacted Beta LaserMike

to solve the problem. After an in-depth consultation and plant

demonstration, the manufacturer selected the LaserSpeed

4000-303L encoder. The LS4000-303L uses advanced,

laser-based technology that does not contact the product

to precisely measure the length of the laminated non-woven

product as its being slitted and reeled onto the rewind roll.

The LS4000-303L projects a unique pattern on the surface of

the product. As the product moves, light is scattered back to

the unit. This information is translated into product speed and

pulses are produced to determine the product length. Length

and speed measurements are captured with better than

±0.05% accuracy.

The Challenges: Slitter/Rewinder Station

The Solution: LaserSpeed® 4000-303L

Critical Process Factors. In addition to delivering more

accurate measurements than the mechanical wheel

encoders, the LS4000-303L had to provide a lower cost of

ownership. Since the LS4000-303L uses no moving parts and

is permanently calibrated, it eliminates the need for on-going

maintenance. Once this encoder is set up, it requires very

little interaction.

Installation. The LS4000-303L is installed on a cross-bar

above the last two idler rollers, just before the rewinder.

The encoder is also positioned perpendicular and 12 inches

away from to the product surface. The LS4000-303L’s laser

beam is projected at the midpoint between the two idler

rollers. The idler rollers are spaced at an optimum distance

to provide the necessary product stability and minimize web

flutter. The LS4000-303L creates a 1.4-inch depth of field or

“measurement zone” to accurately capture the moving

product. Length measurements are outputted via a PLC

to a digital counter.

and at times included up to 9 knives for making 12” cuts.

The rewind/slitter station accommodated extra wide rolls.

Shortage Problem. On a 110 yard roll, the non-woven

product manufacturer was shorting the customer by one (1)

yard. On a 500-yard roll, it was shorting the customer by

approximately seven (7) yards. Inaccuracy at the slitter/

rewinder was as much as 1.4%. This discrepancy was costing

the manufacturer significantly in customer bill-backs. More

importantly, it was costing the manufacturer its reputation.

The non-woven product manufacturer and its customer are very pleased with the results of the LS4000-3030L. This

measurement system has enabled the manufacturer to ship the correct amount of product to its customer on a consistent

basis. This higher level of accuracy from the LS4000-303L has also minimized waste and eliminated bill-backs from the

customer. The system’s measurement accuracy of 0.05% provided a fast payback in savings. Instead of an uncertainty

of 7 yards per every 500 yards with the contact method, the LS4000-303L lowers the possible error to a maximum of

.25 yards on the roll.

© Copyright 2010 Beta LaserMike. All rights reserved. 10/10 Printed in the USA.

Beta LaserMike USABeta LaserMike USABeta LaserMike USABeta LaserMike USABeta LaserMike USA8001 Technology Blvd.Dayton, OH 45424 USAPh: +1 937 233 9935Fax: +1 937 233 7284

Beta LaserMike EuropeBeta LaserMike EuropeBeta LaserMike EuropeBeta LaserMike EuropeBeta LaserMike EuropeUnit 3, First AvenueGlobe Park, MarlowBuckinghamshire, SL7 1YAUnited KingdomPh: +44 1628 401510Fax: +44 1628 401511

Beta LaserMike AsiaBeta LaserMike AsiaBeta LaserMike AsiaBeta LaserMike AsiaBeta LaserMike AsiaUnit 401, Xinmao Plaza,Building 9, No. 99 TianZhou Rd.Shanghai 200233, ChinaPh: +86 21 6113 3688Fax: +86 21 6113 3616

The Results:

Beta LaserMike’s LaserSpeed non-contact encoders are the most accurate,reliable, and cost-effective measurement solution for controlling

product length and dramatically reducing product giveaway.

To learn more, visit: www.laserspeedgauge.com