Roll to Roll Processing: Understanding This Complex System

As you start your small business, there are many things that you can do as a business owner to make tasks like roll to roll processing simpler. While it’s tempting to invest in machines on site and operational training for your permanent employees, this could be a financial mistake in the long term. When you invest in machinery and permanent hires, you’re making a long-term commitment that can be difficult to sustain. However, many small business owners don’t realize that they have alternate options. They believe that in order to offer products and fulfill orders, they must make those long term investments early in their company’s lifespan.

We know that this is not the case. By working with contract manufacturers like CTI, you are able to outsource production and operations without giving up control. You as the business owner will be able to specify what you need. If you work with a toll processing agreement rather than a traditional contract manufacturing agreement, you may even provide the raw materials that we’ll work with. However, we as the manufacturer are responsible for handling the processing itself, as well as the delivery of the final product.

With that being said, let’s explore roll to roll processing from a contract manufacturing and toll processing perspective, as well as the various services that CTI provides. The more you understand about how we can aid you in the development of your business, the easier it will be for you to make a decision about whether we are right for you.

What Is Roll To Roll Processing?

Roll to roll processing is a fabrication system through which flexible rolled substrate materials are imprinted. This is executed through coating, printing, embedding, and laminating, and involves feeding the substrate material through one roller and into another. We call these rollers a web path which winds the substrate material over and over. At this time, devices also apply additives to the substrate material, which helps create a final product.

You may also hear of a roll to roll processing system referred to as web processing or reel to reel processing. The manufacturing approach can vary somewhat depending on the materials used. However, the technology remains essentially the same either way.

What Is A Roll to Roll System?

When we refer to a roll to roll system, we’re discussing the system of processing materials through multiple rollers. The properties of the substrate materials involved change depending on the processes involved. This system is highly reliant on web tension. As the web moves downstream, we must maintain tension perfectly. It must be uniform. The web tension is the main variable in roll to roll systems. If the web tension changes, it affects the entire system. Ultimately, this reflects in the final product as well.

During roll to roll processing, the solution for this issue is automation. Once the roll to roll system becomes automated, web tension can be more easily maintained. Automated web tension also ensures the general efficiency of production. The main alternative factor that affects web tension is the angle at which the material is rolled.

What Services Does CTI Offer?

CTI does not solely offer roll to roll processing, though that is certainly among our available services. We additionally offer:

• Industrial laminating film services
• Adhesive coating services
• Fabric to foam laminating
• Slitting and die cutting

If you are running a small business, it is likely that at some point you will need to execute many different processes. Roll to roll processing is not where your needs will end. Therefore, you may find it much easier to have production and processing for many different systems executed by the same company. If you find that you need slitting and die cutting services, you could have them serviced by the same company that handles your roll to roll processing needs.

How Do I Determine If CTI Is Right For Me?

As a responsible business owner, it will naturally be important for you to make sure that you can trust CTI before making a commitment to working with us. You need to know that you can trust us with processing and production, and the delivery of consistent, high quality results. Fortunately, CTI places a high level of importance on our relationship with clients. We emphasize that relationship from the day that you begin considering us to the day that we complete the contract.

Initially, you’ll begin the process by consulting with CTI. This consultation is free, and gives us the opportunity to assess where you are in terms of production, and how we can best serve you. Not only is this about you getting to know us—it’s about us getting to know you, and ensuring that we are the right fit for your company.

After that initial consultation, the project will advance more into research and development. We use our research teams and equipment to determine the best possible methods for us to complete the assigned project. CTI has manufacturing facilities, laboratories, and production equipment on hand to aid in this process. From that point, we conduct lab testing if necessary, leading into the initial trial run. While we don’t bind you to conduct a trial run, we generally advise it. This allows all those involved to ascertain whether the product is satisfactory.

Once we finish the trial run and approve the process, it is time to move into production. Outsourcing everything from roll to roll processing to adhesive coating services is a great way for you to get the services and products you need without investing as much time or money. Call us at 419-924-5566 or contact us here to start!