Web Handling Fundamentals Workshop

April 14–16 | October 20–22 | Rochester, NY

Hands-On Training in Web Handling Fundamentals

Web handling is a core process engineering discipline behind some of the most productive manufacturing operations in the world. Roll-to-roll processes enable high throughput and efficiency, but when problems occur, waste can accumulate quickly through scrap, downtime, and quality losses.

As manufacturers push toward higher speeds, thinner and more delicate materials, and increasingly clean or hazardous operating environments, the margin for error continues to shrink. Teams must be equipped with the right skills to diagnose issues, control processes, and prevent defects before they impact production. Web Handling Fundamentals provides the practical tools and understanding needed to improve productivity, reduce waste, and confidently scale new products and processes.

This three-day, in-person workshop combines classroom instruction with hands-on laboratory demonstrations to cover core web handling principles. Attendees will learn how to optimize equipment and process designs, reduce waste caused by breaks, deformation, scratches, misalignment, wrinkles, and roll defects, and directly observe web handling concepts applied on operating equipment.

Unlike traditional classroom-only courses, Re:Build Optimation’s Media Conveyance Facility workshops uniquely integrate on-machine demonstrations with technical instruction, allowing participants to directly connect theory to real-world application.

Electronic copies of all training slides will be provided to attendees. Snacks and lunch are provided each day. Following the workshop, participants will also receive a spreadsheet summarizing data collected during on-machine demonstrations.

Who Should Attend?

This workshop is directed towards the technical employees of any level with a need to understand the fundamentals of web handling. The only prerequisite is an aptitude for technology with an interest in the connection between theory and practice.

Workshop Outline

The three-day workshop will aim for a 50-50 split between seminar and lab demonstration time.

Seminar presentations will include:

Web Mechanics and Tensioning

  • Why tension and how much
  • Web physical properties
  • Definition of a tension zone
  • Torque generation

Rollers and Traction

  • Roller basics
  • Roller alignment
  • Roller slip

Nipping Processes

  • Pressure within a nip
  • Nipped system design factors
  • Lamination best practices

Tracking, Wrinkling, and Spreading

  • Perpendicular Entry Rule
  • Causes of web wrinkling
  • Web spreaders
  • Web guides

Winding

  • Winding key process variables
  • Roll pressures and stresses
  • Factors that facilitate roll winding

Lab Demonstrations Will Include:

Lab #1 – Web Mechanics and Tensioning

  • Review of the tension control strategy on the Thin Web Rewinder (TWR)
  • Measurement of web tensile properties
  • Measurement of coefficient of friction
  • Measurement of web camber

Lab #2 – Rollers and Traction

  • Wiki stick for roller tramming and precision level for roller leveling
  • Pi tape for total alignment and roll diameter measurement
  • Micrometer for roller diameter measurement
  • Dial indicator for roller run out
  • Traction measurement using a hand-held Prony Brake on the TWR
  • Traction measurement using the automated Prony Brake on the TWR
  • Roller inertia and bearing drag

Lab #3 – Nipped Systems and Laminating

  • Nip footprint and pressure measurement
  • Strain matching and curl

Lab #4 – Wrinkling, Spreading, and Guiding

  • Perpendicular entry rule
  • Web guiding demonstration
  • Shear wrinkles due to misalignment on the TWR
  • Spreader and anti-wrinkle comparison on the TWR

Lab #5 – Winding

  • Wide web winding
  • Low and high-speed winding
  • Various methods of characterizing roll hardness
  • Winding model predictions

Workshop Instructor

The workshop will be presented by Dr. Kevin A. Cole.

Dr. Cole, a Senior Web Handling Development Engineer with Re:Build Optimation, has a PhD in Mechanical Engineering from the University of Rochester. Dr. Cole developed his expertise in web handling over his 20+ years working for Eastman Kodak Company and led their internal training program on winding and conveyance process fundamentals. He was also an active participant in the OSU WHRC, including chairing their Industrial Advisory Board for four years. Dr. Cole has a rare combination of excellent problem solving and modeling skills, allowing him to comfortably move between production and developmental work.

About the Workshop Facility

The Re:Build Optimation Media Conveyance Facility (MCF) is a 5,000-square-foot space featuring experimental, analytical, and limited production web handling capabilities for both narrow and wide web applications. For more than three decades, the facility has been used to train hundreds of engineers and technical professionals in web handling fundamentals.

The MCF has supported training and problem-solving efforts for teams from many of the world’s leading manufacturers across industries such as films, adhesives, construction materials, specialty chemicals, and advanced materials. Today, the facility continues to serve as a hands-on training environment where theory is directly connected to real production systems.