First of all, I tend to refer to them as spools.
It is a core on which we wind a set width of tape using a traverse winding process. Winding the tape in this way allows for far longer length reels. Making longer feed rolls of a self-adhesive tape applied in a continuous production process is a great advantage. In order to change the roll of tape the entire manufacturing process must be stopped and this comes at a cost, long reels of tape can therefore be a real benefit.
The process starts with slitting or slit/rewinding feedrolls as long as feasible. Our equipment allows us to make feedrolls up to 500m diameter which means we can minimise the amount of splices in the spool. The feedrolls then go on the spooler and are slit into specified width and spooled. We join feedrolls together with a method of usable splicing until the desired length is achieved. The splicing method is key to assure that the final spool will run from start to end without interruptions, and the joint does not cause any bonding failures in the final application.
The actual length of the spool depends on a number of factors.
- Diameter capacity of the user's equipment
Some unwinders or applicators will only allow for spools up to a certain outer diameter
- Width of the adhesive tape
For example we will be able to make a longer spool from 6mm tape width then we can from 25mm tape width.
- Thickness of the material
We can spool anything from very thin filmic or transfer tapes up to 3mm thick foam tapes. Thinner tapes allow for longer length spools.
The equipment we use to produce spools is up to date and technically advanced. We have worked with the manufacturer to fine-tune the software in the machine to suit our process and materials and improve the final product. We currently have 6 spooling heads, each can work individually, so for one run we can choose to utilise only 2 or 3 of the rewind stations or even process different tape widths in the same run.
All this means that whilst we are able, and still have capacity do do large runs, we can also produce small quantities cost-effectively, and quick. It has always been our ethos to produce what our customers need, when it is needed. Larger production runs can reduce the cost per unit, but you can only spend your money once. This does put ownership on us to keep sufficient raw material stocks to keep lead-times down, it also improves cashflow, saves warehouse space and helps our customers to respond to changing demands.
Quality of course is a key element. Not only do we use specified advanced materials from carefully selected manufacturers, we also take great care in the finished product, technically and aesthetically. Finally the packaging is designed to withstand the stresses of national and international distribution.
We convert from our own raw material stock (mostly Seal King brand) as well as offering a contract spooling service. Furthermore we have access to a global network of tape manufacturers and contract coaters to find solutions to more specific challenges.
In the end, we do care a great deal about every aspect of your spools or bobbins, but not what you call them.