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Gloucestershire Printing Company - Mabeg Reel to Sheet Feeding Machine Upgrade

Project Brief

The project was initiated by a printing company in Gloucestershire that was experiencing high maintenance issues with their Mabeg reel to sheet feeding machine. The original caliper brakes were causing the system to produce incorrect sheet lengths, and the maintenance team was being called to the machine daily. The machine builder confirmed that the original hydraulic caliper brakes were being discontinued, necessitating an upgrade.

Old System

The old system was a Mabeg reel to sheet feeding machine that used a Mercedes car braking system and hydraulic caliper brakes. The system was prone to producing incorrect sheet lengths, and the maintenance team was frequently called to fix the machine. The old system was a constant source of problems, and the team was often unsure of what would return the system to working condition.

Disadvantages

  • High maintenance due to frequent breakdowns
  • Inconsistent sheet lengths due to faulty caliper brakes
  • The original hydraulic caliper brakes were being discontinued, requiring an upgrade
  • The old system was a constant source of problems for the maintenance team

New System

The new system replaced the old caliper brakes with new Nexen pneumatic tension brakes. The change from hydraulics to pneumatics allowed for the overlay of a new control system, which did not affect the existing machine. The existing control system resided within the machine PLC, and the upgrade did not risk inadvertently changing the cut to length process while changing the brakes. The new system was fitted in early 2020. Despite the application being tricky due to the high-speed starts and stops along with low tension steady state running, an optimum configuration was soon found.

Advantages

  • Improved reliability and reduced maintenance
  • Consistent sheet lengths due to the new Nexen pneumatic tension brakes
  • The new control system did not affect the existing machine
  • The new system was less than 40% of the cost of the manufacturer's alternative solution
  • The maintenance team reported a significant reduction in issues, with the machine now being the most reliable asset on their site