Roll-to-Roll: The Way to Go

With Northfield Automation Systems (NAS) providing automation globally, the most common factor is that the automation equipment is for roll-to-roll manufacturing purposes.

Despite the availability of larger labor numbers and the lower labor costs in some countries, automation is still being requested. The major reasons behind this are that the products being manufactured are getting increasingly smaller and more lightweight due to the utilization of thinner, more sensitive materials.

Introducing Roll-to-Roll Handling

With products and packaging getting smaller and lighter, it takes thin flexible circuitry to accomplish the product’s functions within smaller-form factors. This is being done with thin flexible films, foils and substrates. With such high-density products on these substrates, it is more challenging for an operator to see defects and handle thin material without damage. Such thin sheets are difficult to maneuver during loading, unloading and transportation through the manufacturing floor.

Enter roll-to-roll web handling automation: a popular method of manufacturing that features better yield results, despite the low labor cost locations of this automation.

Efficient & Effective

Roll-to-roll automation provides manufacturers with a very efficient way to keep manufacturing lines running – either step-and-repeat or continuous process sequences throughout the total process flow of manufacturing (incoming raw material through test/sort/pack). This automation method provides the ability to precisely control speed, tension, alignment and repeatability by having all the process controls automatically maintained and managed. These parameters can also be logged for product traceability throughout the overall manufacturing process for the end customer, as well as for the manufacturer to optimize the product with precision process settings.

Best for the Bottom Line

With dense product nesting to best utilize the material and reduce piece part costs for manufacturing, optimal material handling becomes essential to achieve the best overall bottom line. Creating a wrinkle, crack or crease with manual handling can cause thousands of products to be scrapped out, deeply impacting yield. Some materials have thousands of parts per square foot that can add up quickly to high dollars lost by manufacturers.

At NAS, our goal is to enable the seamless movement of materials through the manufacturing process and help you reach maximum efficiency and maximum quality. Have a project in mind? Contact us today to get started.