TMI offers a comprehensive line of converting services that provide even greater levels of flexibility when ordering vinyl rolls. Converting services range from the simple cutting of strips to complex die cutting patterns. TMI has several state-of-the-art converting machines that ensure precise cuts, precision rewinds and quick turnarounds…even on complex projects. TMI converting services will save time and money by providing a finished product that can immediately be put to use.
Converting services from Vinyl Solutions include:
PVC rolls can be cut manually to any shape and size. All bulk PVC rolls, sheets and panels available through Vinyl Solutions can be manually cut to your desired length. Special cutting of angles or other custom jobs can be requested.
Bulk rolls can be cut and punched into replacement strips on TMI’s automatic cutting machines. A custom-designed press-feed machine replaces the entire manual process of measuring, cutting, punching, and labeling of flexible PVC strips. The end result is strips that can be processed in a fraction of the time compared to manually cut strips. Available from 4" to 16" in width and from 0.04" to 0.25" in thickness.
TMI’s custom die cutting is available for applications requiring large quantities of specially sized pieces. The die-cutter can cut individualized pieces in mass quantity. TMI has five die cutting machines including a fully automatic traveling head press, a beam press, a roller die, and two clicker dies. These machines can handle extremely customized projects or large, standard projects. The automatic die cutting machines are designed to handle pieces as large as 40'' x 60'' and can punch up to 600 cycles per hour. No minimums are required.
Flash cutting utilizes a computer numeric controlled (CNC) head that precisely cuts exact shapes based on a CAD drawing loaded into an onboard computer. Flash cutting is a state-of-the-art process that enables quick, accurate and customized cutting of PVC. Flash cutting makes it possible to accurately cut intricate angles and specifically placed holes.
Using a master sheet or roll, TMI can cut custom-sized pieces up to 60'' wide and 116'' long. To reduce waste, the flash cutting machine makes cuts in a manner that maximizes the PVC - reducing the amount of scrap. Vinyl Solutions flash cutting requires specific PVC sizes. Consult your sales representative for specifics.
Master rolls and slit rolls can be sheeted to exact “length” specifications. Tissue interleaving is commonly used to prevent sheets from sticking together. Sheets are available in sizes up to 54” x 72”. Larger size sheets require special tolerances. Consult your Vinyl Solutions representative for specifics.
Vinyl Solutions offers extra thick panels that range from ¼” to ½” thick. These panels can be cut to your requested size using pneumatically operated cutting machines that create accurate, straight, square and clean cuts up to 17’ in length. Once cut, panels can be re-rolled in the opposite direction to reduce the curl caused by the large rolls.
When PVC is stored in a rolled position, it can often curl to the shape of the roll. Normalizing of flexible PVC panels ensures that they become flattened through a heat-treating process. PVC panels are treated in a 250°F oven. While lying flat in the oven, the material will soften and then maintain the new, uncurled condition once cooled to room temperature. Normalized panels are shipped flat and tissue interleaved on custom made skids to protect the material.
Put Up Changes
TMI’s Vinyl Solutions division can alter roll lengths to specified lengths as determined by the customer. A rewinding machine enables the newly sized roll to then be rewound onto a new core after being cut to the specific size. This service is available on master rolls only.
Often times, PVC can possess a tacky feel that makes the roll hard to unwind and separate. Tissue interleaving places a sheet of lightweight paper between each layer, making the PVC extremely easy to unroll. Tissue can also be applied while slitting or sheeting. Wider sizes can be specially ordered.
Vinyl Solutions’ slitting services can cut PVC rolls and sheets into smaller rolls based on customer specifications. The maximum slit width is 76” and the minimum slit width is 1”. Thickness parameters vary by material (certain materials can be cut more specifically than others.) Consult your Vinyl Solutions representative for specifics.
Electro-static dusting is another option to make the PVC easier to unroll. With electro-static dusting, a layer of dust is applied to the PVC, removing the tackiness and making it easier to separate. Dusting can be adjusted to meet your needs from light (level 1) to very heavy (level 10).
Utilizing a static elimination bar can temporarily reduce a static charge within PVC. This reduced static charge helps prevent dust contamination and static buildup that becomes present when the PVC is unrolled from its core. Static reduction can be applied as rolls are being rewound for put up changes or while being converted. The maximum roll width for static reduction is 76".
RF Heat Sealing
Radio frequency (RF) plastic welding or heat-sealing is a process that can permanently bond PVC and supported fabric sheets. The RF welding process enables TMI to manufacture and tailor larger sheets and curtains with durable hems. Films, supported vinyls, as well as strips and sheets up to .160" thick can all be heat-sealed and seams can vary in width from .50" to 2". Currently, TMI has three heat sealing machines that vary from 7.5 to 20 kw capacity with single bars standard up to 96" wide. These machines are capable of handling jobs of all shapes and sizes. Special heat-sealing dies can be designed and produced to meet your specific requirements.
TMI has an experienced sewing department that can manufacture customized products while increasing the quality, strength and versatility of our PVC. The sewing department can join together material of varying thickness and color. Custom jobs can be completed simply; just provide TMI a specific design, requirement or pattern. Consult your Vinyl Solutions representative for specifics.