Splicing application - Adhesive tape for flying splice

      What Is Flying Splice For Reels?

Flying splice (also known as splice-on-the-fly or roll splicing) is a crucial technique in industries to change reels (paper, plastic film, or fabric) without interrupting workflows.

It involves joining an expiring reel with a new one at full speed using an adhesive tape that ensures a strong and reliable connection.

The main advantage of this technique is the elimination of machine downtime, boosting productivity and reducing idle time. It is indispensable for high-speed processes.

Common Applications:

• Production of coated and uncoated paper

• Printing (newspapers, packaging)

• Manufacturing corrugated cardboard

• Packaging (plastic films, bagging machines)

This method is primarily used in the paper industry, where productivity is critical. Flying splice ensures production continuity and often involves repulpable adhesives designed for specific splicing needs.

Adhesive Usage In The Paper Industry

1. Flying splice

2. Static splice

3. Patch repairs

4. Adhesive detection

5. Reel initiation

6. Reel closure

A Demanding Process

During a flying splice, the connection between two reels must be made quickly, often at speeds exceeding 300 m/min. Industrial adhesives ensure:

• Instant adhesion

• Shear resistance suited to mechanical tension

• Durability under extreme temperatures (high or low), such as those encountered during calendering

      Flying Splice Methods

Traditional Flying Splice:

• Splicing reels at the entrance of a calender or coater.

• Joint formed using a V or W shape.

• Use of double-sided tapes with break tabs.

• Suitable for moderate speeds and standard materials.

High-Speed Flying Splice:

• Splicing reels at the entrance of a calender or coater at high speed.

• Straight joint using splittable double-sided tapes designed for high-speed production.

• Easy and quick setup, reducing operator training time.

• Minimizes waste and errors in joint preparation.

      Adhesive Tapes Adapted To Flying Splice

Key Criteria For Choosing Adhesive Tape:

1. Substrates:
   • Compatibility with materials (paper, cardboard, plastic films, etc.)
   • Smooth, rough, coated, or uncoated surfaces
2. Production Speed:
   • Suitable for high-speed production (> 600 m/min)
   • Instant adhesion to prevent detachment
3. Mechanical Resistance:
   • Shear and tensile strength
   • Dimensional stability to prevent deformation
4. Thermal And Environmental Conditions:
   • Resistance to heat (up to 200 °C), UV, and humidity
5. Type Of Splice:
   • Permanent: Strong, durable adhesion
   • Temporary or repulpable: Recycling compliance or splittable adhesive
6. Adhesive Structure:
   • Backing (non-woven, polypropylene, or unsupported)
   • Optimized thickness to avoid bulking
7. Ease Of Use:
   • Smooth application, precise placement, and invisible splice if needed
8. Standards And Requirements:
   • Compliance with recycling standards (e.g., INGEDE)
   • No adhesive migration, essential for plastic films or sensitive papers
9. Cost And Productivity:
   • Cost optimization and reduced production downtime

Criteria For Choosing Adhesives For Paper Reels

Types Of Adhesive Tapes

Examples Of Adhesive References

      Focus On Repulpable And Hydro-Dispersible Adhesive Tapes

Hydro-dispersible adhesive tapes, designed for paper reel splicing, enable efficient flying splice while meeting growing recycling demands.

They are water-soluble, leaving no residue or obstruction in industrial equipment.

Repulpable adhesive tapes dissolve entirely in the pulper per TAPPI UM213, leaving no residue and integrating seamlessly into recycling processes.

Key Features:

• Thin adhesive profile for smooth transitions
• High adhesion strength for all paper types
• Very high tack for quick restarts
• Exceptional shear resistance for splicing
• Heat resistance up to 200 °C
• 100% repulpable per TAPPI UM213 standards

INGEDE Certification For Recycling :

Certain repulpable adhesives, such as those from the TESA EasySplice range, are certified by INGEDE (International Association of the Deinking Industry).

This certification ensures that these adhesives facilitate the deinking process, which is essential during paper recycling. The process efficiently removes ink, enabling the production of high-quality recycled paper.

Key Benefits Of INGEDE-Certified Adhesives:

• Eco-friendly: Supports sustainable recycling practices
• High performance: Enables clean deinking without residue
• Compliance: Meets stringent industry standards for recycling

The goal is to support the circular economy by minimizing waste and enhancing the recyclability of paper materials.

      Practical Tips For Optimal Flying Splice

1. Use wide adhesive tapes for high-speed splicing to ensure strong bonding.

2. Apply adhesive with a spatula to prevent air bubbles.

3. Leave a 2 mm margin at the reel edge to avoid adhesive creep.

4. Synchronize speed between the old and new reels.

5. Tilt the tape by 5° for a secure flying splice.