In the converting industry, with slitting applications like POS (point of sale), ATM, lottery, liner‑less receipt rolls, and label stock rolls, precision, speed, and consistent roll quality are essential.
There is great variety between different slitting machines. Options include manual vs fully automatic, surface vs center winding, and small vs large format. Choosing the right level of automation is crucial to optimize throughput, reduce labor costs, minimize waste, and improve product consistency. In this comparison guide to small roll surface slitter-rewinder models from Jennerjahn Machine, we’ll look at key terms, the equipment options we offer, some benefits and considerations of automation, and tips for making the right choice for your facility.
Key Concepts & Technology
Before comparing manual vs automatic machine features and capabilities, it helps to understand fundamentally different winding technologies.
- Surface Winding. The rewound roll is supported (i.e., cradled) between driven bedrollers, with a top rider roller that applies a programmable amount of torque and pack force. This provides good control over tension, roll hardness (i.e., pack quality), and winding consistency. Surface winding is often preferred for easier setup changes and lower cost automation.
- Center Winding. In contrast to surface winding, here the roll is wound around a central core and often has different tension or winding dynamics. Center winding is preferred for narrower slit widths and lower wound-in tension.
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Format Size. These are generally defined as follows:
- Small format: Master rolls up to 54 in. wide, 50 in. diameter; finished rolls of small core sizes (i.e., 0.563 to 3.50 in. O.D.), and finished roll diameters between 1.5 and 12 in., and slit widths between 1.5” and 4.0”.
- Large format: Much wider master rolls of 24 to 165 in, usually with core sizes from 1.88 to 3.50 in. O.D., depending on the model, and slit widths from 3.0” to full web widths.
- Automation Levels. Automation can range from entirely manually-operated machines to semi-automatic machines with a mix of manual and automated features, to fully automatic machines that include autoloaders, shaftless rewind, core hoppers, and roll kick-outs.
Jennerjahn Machine’s Models & Levels of Automation
Here’s a breakdown of Jennerjahn Machine’s small format surface slitter‑rewind machines, arranged from lowest to highest level of automation. We’ve noted what the operator must do and compared to what tasks the machine handles to illustrate the differences more clearly.
- JJM – Manual: Operator handles all tasks, each cycle is manual, except for the roll start.
- JJS – Semi‑automatic: Some automation (e.g., magazine autoloader, seal/tabbing station, tail cutting), operator still heavily involved.
- JJF – Fully automatic (single rewinder): Shaftless rewind, core retain bar, autoloader, hopper; runs continuous cycles with minimal operator input.
- DJJF – Fully automatic with dual rewinders: Doubles production with shared core feed/roll removal components.
In practice, the difference between manual and automated machines looks like this:
- Manual (JJM): Operators load cores, insert mandrel, start cycle, transfer finished roll, cut/seal tails, reload mandrels on every cycle.
- Semi‑Auto / Fully Auto (JJS/JJF/DJJF): The machine handles core infeed, sealing/tabbing, roll kick‑out, tail cut. The operator mainly monitors cores, master rolls, and downstream processes.
The Benefits of Increased Automation
There are many reasons to choose automated slitter-rewinder machines for your converting operations, such as:
- Reduced labor and associated costs.
- Fewer repetitive tasks.
- Operators can oversee and manage supporting tasks.
- Higher throughput and less downtime.
- Improved roll quality and consistency.
- Faster setup times for repeat jobs.
- Safer and more ergonomic operations.
Trade‑Offs & Considerations
Before investing in automated or semi-automated machinery, consider these points also:
- Higher capital investment upfront.
- More complex maintenance/training.
- Longer setup time initially for automated features.
- Less flexible for frequent changeover or very small jobs.
How to Choose What’s Best for Your Operation
It can be hard to know what option is best for your organization, especially if your employees are not familiar with automated slitter-rewinder machines. We suggest answering the following questions to get a clear picture of your current operations and needs.
- What is your daily/weekly production volume?
- How often do you change job sizes/formats?
- What are your labor costs and availability?
- How costly is scrap/waste?
- What is your capital budget and ROI expectation?
In general, high volume, repetitive jobs, such as POS rolls, are well-suited to higher levels of automation (JJF, DJJF), while lower volume or frequent changeovers may be more easily compatible with manual or semi‑auto machines (JJM, JJS). If you plan to scale operations up, consider higher levels of automation as a future-proofing strategy.
General Guidelines: Manual vs. Fully Automatic
Jennerjahn Machine offers four small format surface wind slitter‑rewinders. Use the Production Estimator tool on our website to model your cycle times and productivity. Our sales team can also provide expert guidance to help you match the right machine model(s) to your operation.
A good starting point for making your decision is:
| Manual (JJM) | High labor per cycle, lower throughput, more variability, good for flexibility. |
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| Fully Automatic (JJF/DJJF) | Low labor, higher throughput, consistent quality, requires more setup and higher investment. |
Choose Jennerjahn for Slitting Machines, Support, Guidance
Selecting the right automation level depends on volume, job mix, labor, and budget, but it’s not necessarily a simple or easy decision. Manual machines provide flexibility, semi‑auto bridges the gap, and fully automatic delivers high throughput and consistency. At Jennerjahn Machine, we offer a range of machines at different levels of automation, and we can help you determine the best choice for your applications. Contact us to discuss your converting operations and equipment needs, or request a quote.
