A conversion unit converting a first continuous web substrate into a second substrate in the form of converted blanks of predetermined length. On account of cutting tool rotation speed, the web moves at various speeds for cutting the web cut lengths and other aspects of cutting and transport process having a constant input speed. The unit includes a first motorized arrangement for producing a first run driving of the web, a sheeter having rotary tools for cutting the web into blanks, a second motorized arrangement for producing a second run driving of the substrate, the second arrangement being positioned in the immediate proximity of the sheeter, and at least one station having rotary tools for converting the blanks. A speed of rotation of the second arrangement varies during a cycle of rotation of the tools of the sheeter, comprising a phase at constant tangential speed, substantially equal to the speed of rotation of the tools of the sheeter, during which the cut is made, a speed reduction phase, during which a length of the web, dependent on the difference between the length of the blank and an extension of the periphery of the tools, is kept upstream of the second arrangement, and a speed increase phase, during which the substrate is discharged downstream of the second arrangement.

A system for forming a pressware product comprises rollers, a scoring tool, a scoring station actuator, a forming tool, and a forming station actuator. The rollers pull the web along a path having an angle. The scoring tool receives the material from the rollers and includes a vertically shiftable scoring punch with an edge that extends about an outline of the pressware product and a striker plate. The scoring station actuator shifts the scoring tool to form a slot in the web. The forming tool receives the scored web and includes a vertically shiftable positive mold assembly and negative mold assembly. The forming station actuator shifts the positive mold assembly to press against the web and form the pressware product.

A system for scoring a web of a roll of material comprises a plate, a scoring punch, a scoring station actuator, and a controller. The plate has a slot extending about a shape representing an outline of a pressware product. The scoring punch has a protruding blade operable to enter the slot of the plate. The scoring station actuator is configured to shift the scoring punch or the plate to press the blade against the web to form a slot in the web. The controller is configured to direct the scoring station actuator to press the blade to a first predetermined scoring depth within the web.

A system for forming a pressware product from a web of a roll of material comprises a positive mold, a negative mold, a heating element, an actuator, a force sensor, and a control system. The positive mold forms a top surface of the pressware product. The negative mold forms a bottom surface of the pressware product. The heating element is coupled to the positive mold or the negative mold. The actuator shifts the positive mold or the negative mold to cut and form the pressware product in a single stroke. The force sensor detects the forming force applied by the actuator, and the control system directs the actuator to adjust the forming force.

A system for decurling a web from a roll of material comprises rollers, a decurling station actuator, a sensor, and a controller. The rollers are configured to pull the web along a path with an angle. The decurling station actuator is configured to shift one of the rollers relative to the other rollers to adjust the angle of the path. The sensor is configured to sense a characteristic of the roll of material and generate sensor data. The controller is configured to receive a signal representative of the sensor data and direct the decurling station actuator to shift one of the rollers based at least in part on the sensor data.

A device for erecting a flat collapsed carrier, the device comprising a shaft (46) having a longitudinal axis (a). A hub (27) is mounted to the shaft. At least one limb (16a-c) is rotationally mounted to the hub by a pivot coupling. A tool head (14a-c) is mounted to the limb. A drive motor is coupled to the shaft for rotating the hub about the longitudinal axis. The device comprises a first drive mechanism for rotating the at least one limb with respect to the hub such that the distance between the tool head and longitudinal axis can be adjusted.

A converting machine is used to convert sheet material into packaging templates for assembly into boxes or other packaging. The converting machine includes a converting assembly that performs transverse conversion functions and longitudinal conversion functions on the sheet material to create the packaging templates. A fanfold crease sensing mechanism detects the presence and location of fanfold creases in the sheet material. Based on the location of the fanfold creases, the fanfold creases are either cut out of the sheet material, or the sheet material is cut to adjust the position of the fanfold crease in a packaging template.

A method for producing boxes and a method for erecting a box from a box template (3), a box erecting system and a box production system, wherein said method for erecting boxes comprises the steps of: folding (S1) two first bottom flaps (28) and two second bottom flaps (29) of the box template (3), which first and second bottom flaps (28, 29) will constitute a bottom of the box when it is erected and which two first bottom flaps (28) are opposing each other and which two second bottom flaps (29) are opposing each other in the box when it is erected; attaching (S2) the box template (3) to a frame (5); rotating (S3) the frame (5) for wrapping the box template (3) around the frame.

Apparatus is provided for manufacturing a wipe in a three dimensional form out of an essentially flat piece of material. The apparatus produces a blank (12) of essentially flat planar form with a pleat folded on each side. The folded blanks are fed by a conveyor belt (21) to an opening station (22). The opening station comprises a pair of movable pinch rollers (34, 35) which selectively grab individual blanks from the conveyor belt and feed them via belts (32, 33) to a pair of counter-rotating drums (30, 31). The blanks are ejected from the drums, which partially opens them up in the process. The partially open blanks are fed onto a shaped former (37), where the final process of forming the wipe into its chosen three dimensional form is completed.

A system for forming a pressware product comprises rollers, a scoring tool, a scoring station actuator, a forming tool, and a forming station actuator. The rollers pull the web along a path having an angle. The scoring tool receives the material from the rollers and includes a vertically shiftable scoring punch with an edge that extends about an outline of the pressware product and a striker plate. The scoring station actuator shifts the scoring tool to form a slot in the web. The forming tool receives the scored web and includes a vertically shiftable positive mold assembly and negative mold assembly. The forming station actuator shifts the positive mold assembly to press against the web and form the pressware product.