Before stopping
Confirm replacement roll identity, core and width; prepare approved splice materials; protect exposed product and decide how work in progress will be controlled.
Control the transition between approved film reels
Sachet Film Roll Changeover and Splicing
A reel change is a controlled production change, not simply the act of fitting a new roll. The replacement film, winding direction, web path, splice, registration recovery and release checks must all return the sachet process to its approved condition.
Direct answer
How should a sachet film roll be changed?
Use an approved reel specification, follow the machine manual and site isolation procedure, mount the roll in the correct orientation, reproduce the validated web path, make only an approved splice and then re-establish tracking, registration, sealing and cutting before product is released. The first packs after the change should be identified and checked against the normal quality plan.
During the change
Follow safe handling and isolation requirements, mount the reel correctly and keep the web clean, centred and undamaged through the approved path.
Before release
Recover tracking and registration, check seals, code and cut, remove affected packs and document the result under the site procedure.
Freeze the reel specification
The roll schedule should identify film structure, gauge, width, core, maximum outer diameter where relevant, winding direction, print repeat, eye mark, artwork version and supplier batch. Two reels that look similar can track or seal differently if one of these variables changes.
Check reel damage, telescoping, loose winding, contamination and label identity before it reaches the unwind. Quarantine a suspect roll rather than attempting to compensate for a material defect with machine settings.
Plan safe reel handling and access
Reel weight, loading height, access and lifting method should be included in the machine and site assessment. Operators should not improvise lifting or reach into moving web paths. Follow the machine manual and the site’s safe isolation and handling procedure for the installed equipment.
Reproduce the approved web path
Web threading affects tension, tracking and registration. Use a controlled diagram or route label for rollers, dancer systems, brakes, edge guides, photocells, forming sets and pull belts. Confirm the film is centred and that the printed face and sealant face are oriented correctly.
A web that is misrouted can appear to run briefly but create skewed seals, unstable registration, wrinkles or damage as speed increases.
Define an approved splice
A splice should be flat, secure and compatible with the machine path. Specify overlap or butt arrangement, tape, edge alignment, maximum thickness, location relative to the print repeat and how the splice will be detected or tracked. Do not assume a splice can pass every forming, sealing or cutting component without an intervention.
Define whether packs around the splice are automatically rejected, manually removed or held for inspection. The disposition should be traceable.
Recover tracking and print registration
After a reel change or splice, confirm that the sensor sees the eye mark with reliable contrast and that the recipe converts that reference into the correct pack length, seal and cut positions. Clean and align the sensor only under the approved maintenance procedure.
Check artwork position, code zone, tear feature and cut on actual sachets. Do not release product because the eye-mark indicator alone appears stable.
Release the process using sample evidence
Identify the first packs after the change and use the existing sampling plan to confirm dose, seals, leakage, registration, code and cut. Include packs produced during acceleration to normal operating condition. Record the reel identity and any setting change.
If the new reel requires materially different settings, treat the difference as a controlled film or process change and review it against the approved sealing window rather than normalising repeated operator adjustment.
Film roll changeover checklist
- Verify reel identity, specification, condition and winding direction.
- Prepare approved handling and splice equipment.
- Control product, work in progress and affected packs.
- Follow safe stop and isolation procedures.
- Mount and thread the film through the approved path.
- Restore tension, tracking and registration.
- Check seal, code, notch/perforation and cut positions.
- Sample and release packs under the site quality plan.
- Record reel, splice and intervention details.
What to provide when specifying reel handling
| Reel | Width, core, outer diameter, mass, winding direction, structure, gauge and print repeat |
|---|---|
| Change method | Stop-and-change, splice table, manual preparation or an approved automatic option where available |
| Site | Storage, transport, lifting, access, operator position and space for removed cores/reels |
| Quality | Splice-pack disposition, registration recovery, sampling and release requirements |
Registration and web-path instructions are machine-specific. Follow the Lancing machine documentation and site safety procedure for the installed equipment; do not apply a third-party maintenance procedure to a different machine.
Buyer questions
Questions about film roll changes
Can any reel with the same width be used?
No. Structure, gauge, sealant layer, core, diameter, winding direction, print repeat and eye mark can all affect forming, sealing and registration.
Can the machine run through a film splice?
That depends on the approved splice and machine path. Some processes require a stop or reject sequence. Define the method and affected-pack control during the trial.
Why does registration drift after a reel change?
Possible causes include roll orientation, web routing, tension, tracking, eye-mark contrast, sensor position, splice disturbance or a film repeat outside the approved case.
Should the first packs after a change be discarded?
The site quality plan should define identification, sampling and disposition. Packs produced while registration and seals stabilise should not be released without the approved checks.
What makes reel changeover faster without reducing control?
Approved roll data, prepared materials, safe handling equipment, clear web-path instructions, trained operators and a concise release checklist reduce avoidable delay without bypassing checks.
Specify routine film changes
Send the reel schedule, pack drawing and changeover requirement
Lancing can review unwind, access, registration and splice requirements as part of the machine and line specification.