Improving paper converting line uptime

CONVERTING LINES are instrumental to the paper and packaging industries, transforming raw materials like large rolls of paper into finished products. Everyday items such as tissue paper and plastic film are all processed in converting lines. Stages include feeding materials from large rolls — or unwinding — as well as cutting, embossing and packaging the final product.

As converting equipment evolves, original components can become increasingly difficult to source. Many of the systems still running today rely on legacy PLCs, drives, sensors or servo motors – parts that the original equipment manufacturer (OEM) no longer produces. This increases the risk of unplanned downtime when failures occur.

Sweating assets

Running legacy systems for as long as possible – often referred to as “sweating the asset” – is often essential in high-throughput lines. However, it’s a delicate balance that requires planning and expert support. 

A good approach is to keep spare parts in rotation while having a trusted repair partner available on the side. Should a part break, maintenance teams can then swap it for one in their inventory while the other is fixed. 

Preventative maintenance also plays a key role. The times I’ve heard about issues like excessive dust, poor ventilation and outdated cooling causing premature failure in electronic components, like drives and controllers. Such outages can be costly but can be avoided with regular equipment checks.

A strong obsolescence strategy lies on having a good understanding of the OEM origins and the brands involved. Many converting lines, including the ones I’ve encountered across Italy, rely on now-discontinued drives or motors from specific suppliers. 

To stay ahead, maintenance teams must continue to audit the parts installed, tracking which ones are out of production. 

Managing downtime risk

When failure does occur, the biggest concern is availability. The more obscure and outdated the part, the longer the lead time – that is, if a replacement can be sourced at all. 

For instance, If a drive or PLC has been out of production for several years, converting line operators become dependent on third-party suppliers or aftermarket sources.

In some cases, sourcing a like-for-like replacement is the fastest and most cost-effective way to restore production. This is especially true when the addition of a modern part would require engineering changes, software reprogramming or extensive integration work. 

Therefore, maintenance teams must keep stock of high-risk obsolete components and seek out partners that specialise in legacy automation.

When it’s time for an upgrade

Keeping legacy equipment running might seem the most convenient option for converting lines. However, the cost of sourcing and supporting obsolete parts can quickly exceed the price of modern, or ‘active’ alternatives. 

Furthermore, obsolete components may lack sophisticated design features or efficiency improvements, making them more costly to maintain.

Often, upgrading to active products is the most resilient long-term strategy. New generation drives and controllers, for example, offer improved energy efficiency, better integration and digital platforms. 

They also come with a warranty, which most obsolete parts won’t. Cost is usually the biggest hurdle to larger upgrades, but upgrading parts in phases – such as replacing drives while keeping existing motors or PLCs – can help spread costs while ensuring system reliability.

Converting lines are crucial to the paper industry, refining and processing raw materials to produce many of the everyday items we use. Like any production facility, downtime can be costly for converting lines, but a strong obsolescence strategy can help maintenance teams avoid headaches later. 

Working with an experienced legacy automation partner is crucial, as is knowing when to make vital upgrades. 

Christophe Schwandner is export sales manager at CP Automation

www.cpaltd.net