Previous Projects
Coater Drive and PLC Upgrade
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Upgrade and modernize the control system by replacing multiple obsolete ControlLogix processors with a single, up-to-date GuardLogix safety PLC, simplifying architecture and improving long-term supportability.
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Replace legacy Siemens 6SE70 drives with Siemens S120 drives, improving performance, reliability, and parts availability.
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Migrate communications from Profibus to Ethernet/IP, reducing dependence on outdated networks and aligning with current industry standards.
Before:
After:
Lacquer Coating line
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New offset gavure coater
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New UV and IR curing sections
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Drive system upgrade with safety PLC
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New expanded platform to accommodate new equipment
Reverse Roll Coater Gap Adjuster Upgrade
Replaced antiquated taper wedge gap adjusters with new precision gap adjusters that allow for adjustment on the fly without openning nip.
Before Modification:
Taper Sliding Wedges with Top Metering Roll Sliding on Mechanical Gib Slides
Post-Modification Description:
New precision bearing housings are mounted on low-profile linear bearing slides, along with newly designed, significantly larger gap adjusters. The metering-to-applicator roll gap adjusts by 0.001” per turn of the input shaft, and the applicator-to-rubber backing roll gap adjusts by 0.0025” per turn. All mechanical adapters and power-transmission components feeding the gap adjusters are included. ASI supplied drilling fixtures for all required holes in the existing equipment.
The linear bearings are staggered and recessed into the bearing housing to maintain the metering roll’s centerline distance. Each applicator roll bearing housing uses a five-piece construction to allow assembly within the constraints of the current equipment design.
Custom 10” Chucks
Ultra quick solution to allow customer to unwind 10” rolls using standard 6” chucks
Silicone Line Drive and Coater Upgrade
Upgraded control system
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26 line drives
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8 oven fan drives
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Safety PLC controller
Upgraded 5-roll coater
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Improved hydraulic nip control with added safety
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Larger drive train for increased speed
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Automated roll cleaning device
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New high-efficiency mist extraction system
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After:
Client Testimonials
​The machine is running very well and continues to build great rolls through the night. I just spoke with the foreman, and he claims these are the best rolls he has ever seen. The Slitter crew has also confirmed the rolls look great. Thank you. - Justin, Kanzaki Specialty Papers
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