The choice of sheet separation method after lamination has a decisive impact on productivity, edge quality, and production flexibility in automatic laminating lines. Among available technologies, two are the most common: separation using bursting rollers and separation using a flying knife (FK). Each has its characteristic advantages and limitations.
The novelty is the DUO separator system – a solution that combines the advantages of both methods, providing both in a single machine.
But first – a short comparison of these three systems:
Separation using bursting rollers
Advantages:
- High maximum separation speed – depending on the model, it can reach even 60 m/min and more.
- Simple mechanical construction, which translates into lower purchase and service costs.
Limitations:
- Works effectively only with burstable (tearable) films
- Cutting edge quality is often uneven – fraying of the film or uneven tearing occurs.
- Increased risk of sheet damage with films that are harder to separate.
Best application:
mass production using standard burstable films, when the priority is the maximum number of sheets per hour.
Separation using flying knife (FK)
Advantages:
- Full material universality – effectively separates also difficult-to-tear, thick, matte, metallized or non-burstable films, such as nylon or polyethylene.
- Very high edge quality – the cut is clean and precise, without fraying.
- Minimal risk of sheet damage thanks to the controlled cutting process.
Limitations:
- Limited maximum separation speed resulting from the limit of knife travel speed, servo drives and control systems used – in practice, in B1 machines the real separation speed is 20–25 m/min.
Best application:
orders with diverse or difficult films, when the highest edge quality and no defects are key.
DUO system – combining both methods in one machine.
In a laminating line with the DUO system, the sheet web moves along two separation blocks arranged one after the other. Sheets are separated by the selected, active separator, while they pass freely through the inactive one. Switching between separators from the touch menu takes a few seconds – without stopping the line and without physical retooling.
Main benefits:
- No material limitations – when laminating standard burstable films, sheets are separated by bursting at full machine speed, and when laminating difficult films – sheets are cut by the flying knife.
- Elimination of downtime – method change takes a few seconds and does not require stopping production.
- One investment instead of two machines – significantly lower purchase, service, energy consumption and occupied hall space costs.
- Full production flexibility – the machine performs equally well with large series of standard orders and with small batches of typical or demanding films.
One-sentence summary:
The DUO system is the only solution that combines the maximum speed of bursting separation with the full universality of the flying knife – in one machine, without any compromises.
