Created on 11.19
Why Are Roll Ends Cone-Shaped? Root Causes and Solutions
What Does a Tapered Roll Mean?
A cone-shaped roll end is more than just a visual defect. It often results in:
Unstable unwinding and poor alignment
Uneven tension, wrinkles, or film distortion
Breakage during high-speed operation
Poor quality during secondary processing (slitting, laminating, die-cutting)
Main Causes of Tapered Rolls
- Uneven Tension Distribution
If different areas bear different winding forces, the roll will become denser on one side, creating a taper.
- Inconsistent Slipping Force
Traditional winding systems rely on friction pressure. If slitting cores do not receive equal friction torque, winding density varies.
- Delayed Adjustment During Speed Change
As roll diameter increases, torque requirements change continuously. Manual or step-wise torque scaling cannot keep up—causing uneven buildup.
- Mechanical Wear
Examples:
Worn air shafts
Low-response slip rings
Core eccentricity
Aged friction components
The Effective Solution: Controlled Differential Winding
To eliminate tapered edges, precision slip-based winding control is required.
🟢 Recommended Etto Precision Solutions:
Differential Slip Shaft
Dual-Airway Slip Shaft
Center-Pressure Air Slip Shaft
High-Precision Slip Rings System
How Our System Solves the Problem
Issue Traditional System Etto Slip Shaft System
Tension change handling Manual / delayed Real-time automatic compensation
Slitting core slippage Uneven Independent adjustable slip torque
Roll end quality Often tapered Perfect flat ends
Adaptability Material-specific Universal multi-material compatibility
Key Benefits of Etto Precision Slip Shaft Technology
Real-time self-balancing slip torque
Ultra-low to high tension stability
Compatible with film, foil, paper, labels, lithium battery foil, optical film
No frequent manual tuning
Flat roll ends with high winding density consistency
Conclusion
Cone-shaped roll ends are not caused by operator error — they are a sign of:
Insufficient slip-torque balancing and tension control.
Etto Precision slip winding solutions significantly improve end-face uniformity, winding stability, and production efficiency while reducing waste.
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