Embossing roll pattern development responds to market demands

GB Embossing helps tissue producers with aesthetics and function

Embossing roll pattern development fulfills a critical step in the embossed roll repair and production process. GB Embossing provides pattern development completely in-house or in collaboration with customer teams to zero in on precise appearance and performance characteristics.

While some roll patterns remain virtually unchanged for years, new products, rebranding of existing products, and changing market demands make embossing roll pattern development a consistent part of overall product development. Tissue producers, in particular, are always searching for embossing roll pattern designs that serve a functional purpose as well as look good aesthetically.

Experience matters in embossing roll pattern development

Our experienced technicians – some of whom have been with GB Embossing for more than 40 years – have the ability to complete the embossing roll pattern development process from scratch or apply a customer-provided pattern. We can apply patterns to new rolls as well as refurbished rolls as part of our embossed roll repair services.

Getting our team involved early in the embossing roll pattern development process ensures continuity of thought and a singular focus on objectives. The tissue manufacturing process is more complex than ever, with bigger machines running faster speeds than their predecessors.

Pattern development takes equipment variables into account while customizing each pattern to meet specific requirements. Experience in this ever-changing industry and attention to marketplace trends sets GB Embossing apart as a leader in embossing roll pattern development.

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Embossed roll repair saves time and money for converters

GB Embossing provides cost-effective embossed roll repair and re-engraving

As tempting as it is to ride out that shiny new embossing roll until the pattern is no longer viable, converters are finding the sooner they invest in embossed roll repair or re-engraving services, the more they can reduce expenses in the long run. GB Embossing works with preventive maintenance teams to minimize downtime and maximize the value of these capital-intensive assets.

Embossed roll repair can shave a significant amount off costs compared to a fully re-engraved roll or investing in a new roll, sometimes up to 90 percent. Depending on the severity of the damage, our technicians may be able to complete repairs in the field using portable grinders and other tools. We recently performed an in-house embossed roll repair for a major customer that brought that roll back into service within a week.

Our team has expertise in embossed roll repair for rolls of all shapes and sizes, including wide embossing rolls. Catching damage early on may be able to limit downtime for the affected roll to as little as a week compared to 6-8 weeks for a fully re-engraved roll.

Monitor your rolls to limit embossed roll repair needs

GB Embossing recommends our customers monitor the condition of their rolls for early detection of potential issues. Embossed roll repair projects can be as simple as re-chrome plating and as extensive as re-engraving. While re-engraving is a longer and most costly process than a simple repair, it is still significantly less expensive than investing in a brand new roll.

Some of our customers include periodic visits from our technicians as part of their preventive maintenance plan. GB Embossing technicians will produce a status report that aids in schedule and budget creation, along with performing embossed roll repair services as appropriate.

GB Embossing is part of a multi-facility footprint that features best-in-class capabilities through our parent company, Precision Roll Solutions. Our combined over 300,000 square feet of manufacturing space delivers industry-leading design, application, prototyping, and production expertise for embossed roll repair and other continuous web operation-related assets.

Ask about our preventative maintenance plans and emergency services here or call (920) 339-9019 to get started.

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Wide embossing rolls provide additional converting capabilities

GB Embossing produces wide embossing rolls that meet converters’ needs

GB Embossing’s ability to produce wide embossing rolls featuring custom patterns is an example of the flexibility that leaders in the converting industry value in an embossing rolls supplier.

The definition of what qualifies as wide embossing rolls varies by converter and the equipment operating in the mill. We have the ability to engrave virtually any roll length from as short as 2 inches to well over 100 inches, with timely delivery to mills throughout the USA.

Regardless of your definition for wide embossing rolls, GB Embossing’s team is committed to delivering high-quality embossing rolls that meet your requirements. We differentiate ourselves through ease of communication and production excellence that make GB Embossing the supplier of choice for converters worldwide.

Wide embossing rolls help converters adjust to market changes

Consumer products continue to evolve as market conditions dictate. Producers of products such as bath tissue, kitchen towels and folded napkins depend on our expertise with wide embossing rolls and pattern development to create the high-quality look that consumers expect.

Custom pattern development is the key to a successful end product. Our expert technicians can develop patterns that meet customer specifications from scratch, along with using 3D image technology to produce precise patterns from customer-provided samples.

We use a 3D scanner to produce a digital map from your sample and transform it into a format we can use to laser-engrave wide embossing rolls. The exceptional accuracy of this technology produces unmatched pattern reproduction quality, with the added benefit of minimized lead times.

Contact us for a quote regarding wide embossing rolls or other services we offer that maximize your converting profitability.

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Laser Engraved Roll

3D scanner generates reliable images for laser engraved rolls

Laser Engraved Roll
Laser engraved roll in process.

Laser engraved rolls are ideal for tissue and towel test runs

GB Embossing is now able to use 3D image technology to precisely duplicate different depths of patterns in creating or reproducing laser engraved rolls. The process involves laser-scanning the pattern off a roll, flat plate or sample of material, and using that data to generate the software to create a pattern, whether it is male or female. 

These techniques are especially effective when replicating embossing rolls in which a section is worn, or all that remains is a sample of material produced. The laser can scan limited sections where pattern integrity is not lost, and then use those images in the manufacturing process.

Laser engraved rolls are faster to produce than the old tooling methods

In addition to the accuracy that lasers provide, speed is another benefit of this technology. This is especially the case for patterns and customers that are new to our process. The amount of time it takes the laser to create a  pattern on a roll body, by using a 3D scanned image, is significantly less than the traditional tool creation process. Laser test rolls are the norm today. Our customers in the tissue and towel markets now use laser test rolls when they are looking to create new patterns to show their customers. Consistent quality, bolstered by our 3D imaging capabilities, has made GB Embossing the preferred supplier of laser engraved rolls for customers throughout North America. 

Decades of experience paired with new technology

Access to 3D scanning and laser engraving technologies has increased significantly for GB since joining forces with similar industry-leading roll providers MECA Solutions, IR Engraving, and IE Engraving. As part of the Precision Roll Solutions family, we help the world’s leading manufacturers leverage texture and other process variables to make their products more effective and enhance their impact in the marketplace.

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