Efficient Production Solutions
Lüraflex GmbH – Flying Splice Roller New Generation

01.01.2023 Composite materials, e.g. packaging (Tetra Pak) medical products (plasters), construction films (insulation material) consist of different materials and are produced in a coating line. These are supplied in roll form and are to be combined into a composite material in a continuous finishing process. The material ends of the individual rolls are glued together to make the web endless. This process is called splicing.

Flying Splice Roller New Generation
© Photo: Lüraflex
Flying Splice Roller New Generation


This delicate process carries a high risk of production interruption due to web breakage, as errors can occur due to a wide variety of boundary conditions. This costs time, energy and material.

Currently, so-called glue rolls or flying splice rolls are mostly rolls with a soft rubber coating. The softness of the coating is an attempt to conceal defects in the material rolls in order to create a sufficient gluing process. Due to the ever-increasing operating speed of the machines and sensitive materials, this so-called flying splice process is becoming more and more difficult to control. The innovation includes a rubberised glue roller in a sandwich construction with a profile design developed for this purpose.

The design features a soft core in a convex shape and an outer cylindrical hard layer. Radial grooves improve the flow of the process. This new Flying Splice Roll forgives existing defects of the material during the unwinding process. The adjustment of the splicing process becomes much easier. As a result, the material tear-off rate is significantly reduced. This means an optimisation of more economical and energy-efficient production processes, such as time and raw material savings, trouble-free line operation, waste reduction. Extensive tests have been carried out in a pilot plant on model rollers.

Stand 776