A web splice changes thickness, stiffness, surface and tension at one short section of the roll. If the joint is skewed, oversized or poorly secured, it can disturb register, contact a sensor or damage a die path. A roll change also alters diameter and unwind behavior even when material specification is unchanged.
This guide covers a controlled stopped or machine-approved splice workflow. It does not authorize a flying splice or define universal tape, overlap or tension values. Follow the machine, tension-controller, tooling and material supplier instructions.
Decision matrix
| Changeover factor | Evidence | Acceptance |
|---|---|---|
| Material | Grade, width, caliper, coating, direction and roll ID | Matches the approved job |
| Splice | Joint type, squareness, tape and thickness profile | Passes safely through the web path |
| Unwind | Core, chuck, brake and roll orientation | Roll is centered and secured |
| Tension/register | Setpoint history, diameter entry and mark/cut reference | Transition remains controlled |
| First cuts | Position, cut quality, waste release and splice passage | Approves continued production |
Control both outgoing and incoming rolls
Verify job, material code, width, coating/print side, machine direction, core condition and roll IDs. Inspect telescoping, edge damage, loose winding and contamination. Do not splice materials that have not been approved as the same production input.
Record remaining diameter and the incoming full-roll diameter where the controller uses them. Maxcess notes that new-roll and splice features can change tension-control output; use only the configured machine function and preserve its baseline.
Prepare a square low-profile joint
Stop and isolate according to the threading procedure. Align web edges against a controlled datum so the joint does not introduce lateral step or angle. Use the specified splice style and compatible tape; trim loose corners and prevent adhesive from extending into rollers or tooling.
Measure the finished joint thickness and inspect both faces. Do not staple the web or add multiple tape layers to gain confidence. Mark the splice visibly at the web edge if the machine procedure uses a detection or manual tracking mark.
Load and center the new roll
Inspect shaft, chuck, core, brake and edge references. Secure the roll using rated handling equipment and confirm unwind direction. Center it to the established web line rather than a frame edge that may not be the process datum.
Thread through the exact roller and sensor path shown by the machine diagram. A missed idler changes wrap angle and tension behavior. Keep the splice away from sharp guides and verify no tape edge can lift.
Control tension and register transition
Restore the approved job settings and enter new-roll information only where required. Run slowly while monitoring load-cell or dancer response, brake output, edge position and register. Do not compensate a skewed splice with permanent guide or register offsets.
Track the joint location and reduce risk before it reaches precision tooling. If the machine procedure requires opening impression or diverting the splice, follow it exactly. Never let an unapproved thick joint pass through a closed die nip.
Approve first cuts after the splice
Inspect cut position, cross-web consistency, backing/anvil marks, stripping and blank delivery before and after the joint. Record any transient tension or register alarm and how many repeats are needed to recover. Segregate splice-area material according to the quality plan.
Save roll IDs, splice materials, controller state and labeled samples. Send HANNAI the web-path photo, joint dimensions and register trend when changeovers remain unstable. The linked unwind guide covers core and brake preparation.
Technical references
- Maxcess MAGPOWR tension controller manual — general component guidance; the installed machine documentation remains controlling.
Related machine and guide
Review the 850 roll die cutting machine for machine context, then use the reel loading and unwinding guide for the adjacent check. Browse all Buyer Guides when building a wider project checklist.
Frequently asked questions
Can any tape be used for a web splice?
No. Adhesion, thickness, temperature and material compatibility must suit the approved process.
Should register offset hide a skewed splice?
No. Correct joint geometry and web presentation first.
Can every splice pass through a closed die nip?
Only if the machine and tooling procedure explicitly approves it.
What should be retained after changeover?
Roll IDs, splice construction, tension/register evidence and marked first-cut samples.
Review your machine configuration with HANNAI
Send the machine model, project reference, component labels, drawings, photos and a description of the required result. We will clarify which details must be confirmed before a quotation or technical recommendation.