In today’s packaging market, printed film quality is just as important as strength or clarity. Misaligned prints can cause waste, reduce shelf appeal, and disrupt automated packaging systems.
Accurate film alignment is key to achieving clean, consistent branding on every roll.
Why Alignment Matters
When film drifts off-centre, printed designs shift out of register. This leads to blurred logos or uneven seams, problems that can result in rejected rolls and lost production time.
Proper alignment ensures the print stays true from start to finish, even at high line speeds. See Why Blown Film Needs Precise Web Guiding for a detailed look at how guiding improves accuracy.
How to Improve Film Alignment
- Use Active Web Guiding Systems
Modern systems use sensors to monitor film position and make automatic adjustments in real time. This eliminates manual corrections and keeps registration consistent.
- Maintain Correct Roller Setup
Roller alignment and pressure are just as important as guiding sensors. Check all turning bars and idlers for smooth rotation and even wear. Swallow’s Turning Bar & Idler Systems provide precise film control through the entire web path.
- Control Tension and Speed
Uneven tension can cause the film to stretch or shift. Use consistent winding speeds and keep nip pressure balanced.
Avoiding Common Issues
If colour drift or overlapping prints appear, inspect the guiding sensors and rollers. Dirt, static, or vibration can affect readings. Clean sensors regularly and ensure roller bearings move freely.
For legacy lines, small automation upgrades can dramatically improve print accuracy and reduce setup time.
Final Thoughts
Perfect printing starts with perfect alignment. Reliable web guiding, smooth roller systems, and even tension control work together to produce consistent, high-quality packaging film.
Swallow continues to support converters and film producers with advanced handling systems that enhance quality, reduce waste, and protect your brand reputation. Speak to an expert today.
Need to optimise your web processing setup?
Our experienced team at Swallow Machinery is ready to advise on the best ancillary machinery - from web guiding and tension control to air-expanding reel shafts. Get in touch today to explore how we can support your continuous manufacturing needs.
