This document discusses issues with excess and damaged paper rolls in paper mills and describes a solution called RollRazor. It notes that 7% of paper produced, or 7.2 million short tons per year in North America, needs to be reworked. Slitter/rewinders have limitations in addressing this issue. RollRazor is presented as a new system that can cut paper rolls robotically between 10-132 inches wide at rates faster than existing technologies, addressing the paper waste problem in mills. It has set records processing up to 84.7 short tons of paper in under 7 hours with one operator.

1. A revolution in roll converting
RollRazor

2. The challenge
 Customer change orders
 Over/under inventory
 Transportation issues
 Damaged rolls
 Roll stocking programs
 PM trim rolls
 Unassigned mill inventory
 Paper returned from printers
 Quality issues
90-95% of a mill’s production goes directly to
pressrooms. The balance does not - Why?

3. Results
 344 mills produce paper in North America
 They generate 102 million short tons/year
 7% = 7.2 million short tons of paper to be reworked in North
American paper mills alone
 For a 500,000 ton Paper Mill that 7% is equal to 35,000 short
tons/year

4. What happens to the paper?
 Put into warehouse for “future orders”
 Sell into seconds market
 Pulper for recycling
 Convert it

5. Slitter/rewinders have limitations
Slow — most rewinders average One roll/hour
Expensive
Rolls are limited to the width of the machine
Does not retain original mill wind
Printers do not like to use its rolls
Inefficiencies on narrow web rolls
Difficultly with light b/w paper

6. Generation III – RollRazor Pkg.

7. RollRazor Models
Above Floor
In Floor

8. Roll width 10” to 132”
Roll diameter 36” to 50”
Maximum roll weight 13,000 Lbs.
Saw blade size 64”
Saw blade thickness 3/8”
Smallest cut 1”
Power 480v / 3ph
Pneumatics 95 PSI (dry)
Avg. cutting heat 77f
Avg. finishing heat 80f
Current db levels 84
Footprint 325 sq ft.
Dust collection Integrated
Specifications

9. World’s first robotic finishing Station
ABB & Mapleroc Partnership

10. Dust Collection

12. Generation III (In-Floor) RollRazor

13. Record setting performance by ONE operator!
Max # of rolls cut in 1 hr = 5 (10/05, 2/06, 3/06, 10/06)
Most rolls cut in 8 hr. shift 36 (10/20/05)
Smallest rolls cut = 15.5” (10/06/05)
Largest roll cut = 130.6” (10/12/06)
Max # tons cut in 1 hr. = 14.6 st. (4/5/06)
Max # of tons cut in 6.9 hrs. = 84.7 st. (10/11/06)

14. Patents
Canada
United States
Sweden
Finland
Germany
Italy
U.K.
France
Spain
India
China
Korea
Japan

15. The End