An apparatus and method is provided for single transfer insert placement. The apparatus receives continuous web material and cuts a discrete section or pad from the web. The pad is then supported on a single transfer surface. The single transfer surface then may spin the supported pad to a desired angle and provide the pad to a receiving surface at a desired interval. The web material can be cut to different insert lengths and the placement location varied.

An apparatus and method is provided for single transfer insert placement. The apparatus receives continuous web material and cuts a discrete section or pad from the web. The pad is then supported on a single transfer surface. The single transfer surface then may spin the supported pad to a desired angle and provide the pad to a receiving surface at a desired interval. The web material can be cut to different insert lengths and the placement location varied.

A method of forming a web includes directing a first discrete segment at a first speed to a first pick-up location. The first discrete segment is transferred from the first pick-up location to an application location using a first segment transfer device. A second discrete segment is directed to at a second speed to a second pick-up location. The second discrete segment is transferred from the second pick-up location to the application location using a second segment transfer device. The first and second discrete segments are attached to each other at the application location to form a web.

A web cutting system is provided for use with a single transfer insert placement mechanism having at least one puck for transferring a discrete web and a continuous web feeding mechanism for feeding a continuous web wherein first and second rollers having substantially parallel axes and being aligned with one another form a nip at their juncture, an anvil is attached to one roller, a die is attached to the other roller, a vacuum source is coupled to one of the rollers, a plurality of vacuum apertures is formed in the same roller. One of the rollers is positioned adjacent to the single transfer insert placement mechanism and to the continuous web feeding mechanism. The continuous web is applied to one roller and at least one discrete web is transferred from the puck to the same roller after which a die cutting process of the webs occurs at the nip.

A web cutting system is provided for use with a single transfer insert placement mechanism having at least one puck for transferring a discrete web and a continuous web feeding mechanism for feeding a continuous web wherein first and second rollers having substantially parallel axes and being aligned with one another form a nip at their juncture, an anvil is attached to one roller, a die is attached to the other roller, a vacuum source is coupled to one of the rollers, a plurality of vacuum apertures is formed in the same roller. One of the rollers is positioned adjacent to the single transfer insert placement mechanism and to the continuous web feeding mechanism. The continuous web is applied to one roller and at least one discrete web is transferred from the puck to the same roller after which a die cutting process of the webs occurs at the nip.

Personalized printed products are produced in which at least one individually printed sheet is combined with conventionally printed sheets. A plurality of stacks of conventionally printed sheets are made available. In addition, a print material web is made available that contains individual sheet segments and respectively one marking based on information received from a database, or a roll is provided which contains a pre-printed material web containing the sheets segments with respective markings. The markings on the individual sheet segments are read out and information read from the markings is used for selective gathering of conventionally printed sheets that are needed for the personalize printed product. Following the readout of the markings, individually printed sheets are cut from the print material web. Respectively at least one individually printed sheet is supplied to the associated, conventionally printed sheets, corresponding to the information read from the marking from the one individually printed sheet.

Personalized printed products are produced in which at least one individually printed sheet is combined with conventionally printed sheets. A plurality of stacks of conventionally printed sheets are made available. In addition, a print material web is made available that contains individual sheet segments and respectively one marking based on information received from a database, or a roll is provided which contains a pre-printed material web containing the sheets segments with respective markings. The markings on the individual sheet segments are read out and information read from the markings is used for selective gathering of conventionally printed sheets that are needed for the personalize printed product. Following the readout of the markings, individually printed sheets are cut from the print material web. Respectively at least one individually printed sheet is supplied to the associated, conventionally printed sheets, corresponding to the information read from the marking from the one individually printed sheet.

A rotary drum apparatus comprises a drum that is rotatable about an axis of rotation. The apparatus comprises a first set of first shell segments having a first number of first shell segments. Each first shell segment is releasably connectable with the drum and has an outer surface. The outer surfaces of the first shell segments combine to form a continuous first outer circumferential surface defining a maximum radial distance from the axis of rotation. The apparatus comprises a second set of second shell segments having a second number of second shell segments. Each second shell segment is releasably connectable with the drum and has an outer surface. The outer surfaces of the second shell segments combine to form a continuous second outer circumferential surface located within 10% of the maximum radial distance. The first number of first shell segments is greater than the second number of second shell segments.

A rotary drum apparatus comprises a drum that is rotatable about an axis of rotation. The apparatus comprises a first set of first shell segments having a first number of first shell segments. Each first shell segment is releasably connectable with the drum and has an outer surface. The outer surfaces of the first shell segments combine to form a continuous first outer circumferential surface defining a maximum radial distance from the axis of rotation. The apparatus comprises a second set of second shell segments having a second number of second shell segments. Each second shell segment is releasably connectable with the drum and has an outer surface. The outer surfaces of the second shell segments combine to form a continuous second outer circumferential surface located within 10% of the maximum radial distance. The first number of first shell segments is greater than the second number of second shell segments.

Systems and methods utilizing stationary and/or moveable cutting components provide limited interference with web processing operations, such as pad spin and pitch alteration. Heat, laser, fluid, or mechanical cutting operations may be used, including respectively, a heated element (e.g., wire, ribbon, bar, or embossing or perforating element) that may be triggered inductively, water or steam jets, or improved knife/anvil cooperation.