With wider presses and the requirement to run more ribbons, this problem was exacerbated. Goss International engineering realized that improvements were needed in ribbon tension control. They developed a multi-ribbon transport model to better understand the folder’s ribbon dynamics. This mathematical model consists of equations explaining the stress and strain relationships in ribbons, as they travel through the folder.

Utilizing this fundamental knowledge, they were able to precisely define the parameters required for the proper nip material that would accommodate changes in thickness without changing the amount of pull imparted to the ribbon stack.

A new variable-speed drive system was also developed to complement the new material. The improved nip pressure created by the new rollers, required that the rotational speed of the nip roll shaft be more precisely controlled. The new drive system also provides on-the-run speed adjustment and extremely accurate control of the tension in the slit ribbons leading to the RTF.

The Zero-slip nip technology is available on new Goss® commercial folders or as a retrofit for existing folders. It is presently offered on PFF-2 and PFF-3 former folders.

Reduced makeready time
Manually adjusting folder nip pressure during makeready typically takes an operator 10 minutes for each set of pinch rollers. With two formers that could be a total of 20 minutes. This requirement is eliminated completely with the new technology, and the savings is compounded, as the operator is free to complete other makeready tasks.

Increased operating speed
Operating speed is increased due to the ability to eliminate the slack ribbon condition associated with the ribbon which is closest to the former board. Field results have shown significant increases in running speed, with a range between 2% and 15%.

Increased nip roller life
With the new, proprietary material, the Goss nip rollers last up to 1 1/2 times longer than previous rollers, reducing maintenance costs substantially.

Improved product quality
The print-to-cut error is minimized due to the ability of the Zero-slip nips to isolate the upstream ribbons from the cutting function. Improved ribbon control minimizes wrinkles over the former nose. Combined, these improvements equate to a more consistent finished product appearance.

Reduced start-up waste
Start-up waste is reduced due to the speed in which the ribbon tension is obtained, and to an improvement in the number of times that the web breaks during re-start after a press stoppage.

"we have also seen operational improvements in areas that were unexpected. The time saved during makeready was enough of a justification to pay for the upgrade in less than two years, but the added benefit of increased speed and reduced waste brings the ROI in even sooner."

Although PIA/GATF sponsors and coordinates the award process, PIA/GATF does not make the selections. A special committee comprised of industry technical experts carefully reviews the nominations and makes the selections.

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