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ROI & Waste Reduction

Return on Investment:

In most applications automatic splicing has a quick return on investment (ROI). Automatic splicing equipment pays for itself by increasing the productivity of the production line and decreasing the waste resulting from roll change. Even in applications with short jobs and frequent roll changes automatic splicing has extremely good payback. Short runs do not reduce end of roll stops, but rather typically result in more partial rolls being unloaded and changes happening soon after starting a small diameter roll. Often an automatic splicer dramatically increases productivity on a packaging line which runs primary brand and private label brands, by allowing the job change to happen with no down time and minimal waste.

A typical high production packaging line produces for 6,000 hours per year with 4,500 roll changes. The expected down time of 6 minutes per roll change results in 27,000 minutes of lost production. Additionally each roll change creates waste which nonstop production with in-register splicing eliminates. If each splice creates 41 bags of waste, auto splicing eliminates 40 bags 4,500 times per year (180,000 bags of waste eliminated). If your plant also runs private label brands, these changes can also be made on the fly. If you average 5 of these changes per day and run 300 days per year, you will have an additional 1,500 splices with which to eliminate down time and waste.

Please click on the ROI calculator below to help you calculate your payback from adding automatic splicing.

It should be noted that increased productivity offers an extremely strong payback when the production and packaging capacity are balanced thus added hours of packaging result directly in more production rather than added wait time on the packaging line while waiting for product.

Waste Reduction:

The typical waste on a butt roll coming off of a Butler Automatic Splicer with the core sensing splice actuatuion option is inbetween 3 and 7 feet. In the picture the waste material left on the roll is 4 packages. Only the unit with the splice tape is wasted when the new roll is spliced in. Automatic Splicing is an efficient and effective way to eliminate excessive and costly waste material from your operations.