Manufacturing uniform packaging materials through rolling processes presents significant technical challenges, with thickness variations commonly ranging from 2-5% across sheets and dimensional inconsistencies affecting both machine direction and cross-direction uniformity. These variations impact not only the material's mechanical properties but also its performance in downstream converting operations.

The fundamental challenge lies in balancing material flow control during rolling while maintaining consistent pressure distribution across the full width of the sheet.

This page brings together solutions from recent research—including multi-pass roller systems with adjustable spoke arrangements, width compensation devices that account for material expansion, and automated alignment mechanisms for edge control. These and other approaches focus on achieving dimensional stability while optimizing production efficiency in modern packaging operations.

1. Paper-Based Roll-Shaped Tissue Packaging with Selective Heat Sealant Coating

DAIO PAPER CORP, 2024

Packaging body for roll-shaped sanitary tissue that prevents damage to the tissue rolls during packaging and handling without using plastic. The packaging uses a paper base material coated with heat sealant on the contact surfaces with the rolls except for the roll periphery. This avoids contact between the heat sealant and roll surfaces that can damage tissue quality. The coated areas are the roll-tissue contact surfaces and corners, not the roll periphery. This allows rolling, stacking, and transport without contacting the heat sealant.

2. PET Packaging Sheet Rolling and Laminating Equipment with Adjustable Multi-Pass Roller and Spoke Arrangement

Shenyang Yingye Plastic Packaging Products Co., Ltd., SHENYANG YINGYE PLASTIC PACKAGING PRODUCTS CO LTD, 2023

PET packaging sheet rolling and laminating equipment with automated coating and lamination. The equipment has a base with rollers and pressure spokes. Between the rollers and spokes is a sheet transportation area. The rollers and spokes are arranged in groups. Above the spokes are rolling spokes. The rollers and spokes are positioned to allow multiple passes for better lamination. Sheets enter on a front conveyor, are coated, and exit on a rear conveyor. The conveyors, rollers, and spokes are adjustable to prevent sheet misalignment. A cutting device between the spokes trims excess coating. Above the front conveyor is an auxiliary roller with adjustable height to press sheets for better transport.

3. Packaging Material Bonding Device with Rotating Shaft and Rolling Mechanism for Air Bubble Elimination and Material Trimming

Hangzhou Hengtai Packaging Products Co., Ltd., 2023

Improved packaging material bonding device that prevents wrinkles and excess material in laminated packaging by using a rolling mechanism to squeeze out air bubbles and trim excess material. The device has a workbench with a fixed upper surface, a rotating shaft running through it, and a rolling device connected to the shaft. A driving motor rotates the shaft and the rolling device extrudes the materials together to squeeze out air and trim excess. An adjustment device holds the materials in place on the workbench. This prevents wrinkles and improves quality of laminated packaging.

CN218906599U-patent-drawing

4. Width Compensation Device for Laminated Materials with Expansion Estimation in Rolling Mills

TOSHIBA MITSUBISHI-ELECTRIC INDUSTRIAL SYSTEMS CORP, 2022

Device to improve width accuracy of laminated materials like paperboard by compensating for expansion when rolling. The device calculates an estimated width expansion of the laminated material when it's caught in the horizontal rolling mill. This estimated expansion is then used to compensate the amount of slack in the vertical rolling mill to counteract the expected width growth. This prevents over-widening of the laminated material when it's caught between the horizontal rollers.

BR112017011610B1-patent-drawing

5. Rolling Device with Pivoting Closing Elements and Recessed Parallel Plates for Edge Rolling of Flat Packaging Materials

BRUNNER FRANZ, 2021

Rolling device for packaging machines that allows rolling up the side edges of flat packaging materials like foil or paper to create custom-sized packages without waste. The device has parallel plates with recesses and pivoting closing elements. The plates have recesses matching the closing elements. The closing elements pivot between an open position and a working position. When the packaging material is fed over the device, the closing elements close the recesses on the plates, rolling up the side edges of the material. This allows adjusting the size of the packages without excess material.

DE102020117412B4-patent-drawing

6. Aluminum Foil Rolling Process with Multi-Step Sequence and Variable Roll Roughness and Pressure Levels

JIANGSU DAYA ALUMINUM CO LTD, 2016

High peel strength aluminum foil rolling process for food packaging applications like dairy products. The process involves using a multi-step rolling sequence with specific roll roughness and pressure levels to produce thin aluminum foil for food packaging with improved peel strength. The coarse rolling steps have higher pressures and rougher rolls to reduce thickness, followed by finer rolling with lower pressures and smoother rolls to final thickness. The rolling is done at specific temperatures. This process produces thin aluminum foil for food packaging with high peel strength for composite packaging.

7. Laminating Roller with Peripheral Groove for Lateral Displacement of Elastic Surface

TETRA LAVAL HOLDINGS & FINANCE, 2016

Laminating roller for packaging material production that reduces tucking and ruptures in pre-punched holes to improve yield and quality. The roller has a groove along its periphery that allows the elastic surface to displace laterally instead of tucking during lamination. This prevents wrinkles and ruptures in the flexible membrane covering the holes. The groove design prevents trapped air from causing explosions and ruptures. The resulting packaging has intact barrier film in the hole area for better sealing.

8. Roller with Circumferential Groove for Packaging Laminate Membrane Stabilization

TETRA LAVAL HOLDINGS & FINANCE, 2015

Packaging laminate manufacturing process and roller design to reduce ruptures and improve yield when making packaging with pre-punched holes. The roller has a groove around its circumference to allow the elastic roller surface to displace laterally and prevent tucking of the membrane formed by the layers covering the holes. This reduces ruptures and wrinkles in the membrane. The groove design also prevents trapped air from causing explosions and ruptures. The packaging laminate itself has air channels between the barrier film and outer polymer layer around the holes to stabilize and reinforce the membrane. This prevents ruptures and improves quality.

Get Full Report

Access our comprehensive collection of patents related to this technology