If you work in sign making, vehicle graphics or wide format printing, you’ll know that producing a great print is only part of the job. The finishing and application process can have just as much impact on the final result.
This is where the Rollover flatbed applicator can make a real difference.
As a technician at Signmaster, I install, service and maintain Rollover machines for customers using them in real production environments. Over the years, I’ve seen how much difference the correct setup, technique and maintenance can make to the performance of a Rollover.
In this guide, I’ll cover what a Rollover is, what it can be used for, how to get the best results from it and some of the common issues I look out for when installing and servicing these machines.
What is a Rollover?
A Rollover is a flatbed applicator designed to make the application and mounting of printed materials more accurate, consistent and efficient.
Rather than trying to manually apply vinyl, application tape or printed graphics onto a substrate, the Rollover provides a controlled working environment that helps the operator achieve a cleaner and more consistent result.
At Signmaster, we use the Rollover as part of the wider range of wide format finishing equipment, helping sign makers and print businesses improve the way they handle applications after printing.
The machine can be used for tasks including applying application tape to vinyl, mounting vinyl onto boards and laminating materials.
What can a Rollover be used for?
One of the biggest advantages of a Rollover is its versatility.
Depending on the type of work you are producing, a Rollover can be used for:
- Applying application tape to vinyl graphics
- Mounting printed vinyl onto boards
- Laminating printed materials
- Applying graphics to rigid substrates
- Producing signage
- Working with vehicle graphics
- Improving consistency when applying large graphics
- Reducing manual handling during finishing
For businesses producing a mixture of signage, vehicle graphics, displays and wide format prints, having a dedicated application table can make the finishing process much more controlled.
Why use a Rollover instead of applying vinyl by hand?
This is one of the questions I get asked when speaking to customers.
Manual vinyl application is something experienced sign makers can become very good at, but when you are working with larger graphics, consistency becomes increasingly important.
With a Rollover, the material and substrate can be positioned on a flat working surface, allowing the operator to control the application process more accurately.
From a technician's perspective, I also find that the machine can help create a more repeatable workflow. Once the operator understands the correct setup and technique, jobs can be completed with less trial and error.
For a busy sign shop, that can be particularly useful when producing multiple graphics that need to look consistent.
Installing a Rollover: what should you consider?
One of the most important parts of getting a Rollover working correctly actually happens before you start using it.
Installation and positioning matter.
When I install a Rollover, I look at more than simply getting the machine into the building and switching it on.
The available floor space, access to the machine, working area and the operator's workflow all need to be considered.
You need enough room around the Rollover for the operator to work comfortably and safely. You also need to think about the size of the materials being handled.
This is particularly important when a customer is moving from manual application to a larger professional flatbed applicator.
A machine may physically fit into a room, but that doesn't necessarily mean it is going to be practical to operate there.
Getting the Rollover set up correctly
A proper installation is important because small setup issues can become frustrating problems once production starts.
During installation, I check the machine is correctly positioned and set up before handing it over to the customer.
I also make sure the operator understands the basic operation and, where required, provide training on the machine.
This is something I always recommend with finishing equipment.
Knowing which buttons to press is very different from knowing how to get the best results from the machine.
How to get better results from a Rollover
The machine itself is only one part of the equation.
The operator's technique makes a big difference.
Here are some of the things I recommend:
1. Keep the working surface clean
Dust, dirt and debris can cause problems when you're applying vinyl or mounting graphics.
A clean working surface helps prevent unwanted contamination underneath the material.
2. Take your time with positioning
Don't rush the initial positioning of the graphic.
A few seconds spent checking alignment can save considerably more time later if the graphic has been applied incorrectly.
3. Understand your materials
Different vinyl, application tapes, laminates and substrates can behave differently.
Get to know how your materials react and adjust your technique accordingly.
4. Avoid unnecessary pressure
More pressure isn't automatically better.
The correct technique is about controlling the application rather than simply forcing the material onto the substrate.
5. Keep the machine maintained
Like any piece of production equipment, a Rollover should be looked after.
Regular checks and proper maintenance can help identify potential issues before they develop into larger problems.
Rollover maintenance: what should you check?
One of the biggest mistakes I see with production equipment is waiting until something goes wrong before looking after it.
Preventative maintenance is much easier than dealing with an unexpected production stoppage.
With a Rollover, keeping the machine clean and checking its condition regularly should form part of your normal workflow.
I recommend operators pay attention to:
- The general condition of the machine
- Checking oil level in compressor
- The working surface
- Moving components
- Rollers and application components
- Any unusual noises or resistance
- Damage or wear
- General cleanliness
- Changes in how the machine operates
If something feels different from normal, don't simply ignore it.
A small issue can sometimes be much easier to resolve when it is identified early.
Common Rollover problems
As a technician, some of the problems I deal with are not necessarily major machine failures.
Sometimes the issue comes down to setup, operation, materials or maintenance.
For example, if an application isn't producing the expected result, I would look at the complete process rather than immediately assuming the machine itself is faulty.
I would consider:
Is the material positioned correctly?
Is the substrate suitable and properly prepared?
Is the machine being operated correctly?
Is there any contamination on the working surface?
Has anything changed recently?
This is why professional servicing and technical support can be useful. Diagnosing a problem properly is often about looking at the complete workflow.
Rollover troubleshooting: where should you start?
If your Rollover isn't behaving as expected, I would recommend starting with the basics.
First, check that the machine is clean and correctly set up.
Then look at the material and substrate you are using.
If the problem is still present, check whether there has been any recent change to the machine, materials or application process.
If you are still unable to identify the cause, it's worth getting the machine checked by a qualified technician rather than continuing to operate it incorrectly.
Trying to work around a developing mechanical problem can sometimes turn a relatively straightforward repair into a bigger one.
How often should a Rollover be serviced?
The appropriate servicing schedule will depend on how heavily the machine is used and the environment it operates in.
A Rollover being used every day in a busy production environment will naturally experience more wear than one being used occasionally.
Rather than waiting for a breakdown, I recommend businesses consider preventative servicing as part of their overall equipment maintenance plan.
From a technician's perspective, preventative maintenance gives you the opportunity to identify wear and potential problems before they cause unnecessary downtime.
Is a Rollover worth having in a sign making business?
For businesses regularly applying vinyl, mounting graphics or laminating materials, a Rollover can become an important part of the finishing workflow.
The biggest benefit isn't necessarily one particular feature of the machine.
It's the consistency and control it can bring to the application process.
If your business is producing increasing volumes of graphics, moving from entirely manual application to a dedicated flatbed applicator can also help create a more repeatable production process.
Rollover training
Getting the most from a Rollover isn't simply about knowing how to turn the machine on.
At Signmaster, Rollover training can cover application tape, mounting vinyl to boards, laminating and getting the most from the machine's versatile bed. Training can also include maintenance, troubleshooting and practical advice from a technician.
This type of hands-on training can be particularly useful when a business has just invested in a Rollover or has new members of staff who need to learn the correct application techniques.
Rollover Classic vs Rollover Flexi
Signmaster supplies different Rollover configurations, including the Rollover Classic and Rollover Flexi.
The right machine will depend on the type and size of work your business produces, as well as the space available and the applications you need to carry out.
When choosing a Rollover, I would always recommend considering the complete workflow rather than simply choosing the largest machine available.
Think about:
- The size of your typical graphics
- The substrates you work with
- Your production volume
- Available floor space
- The type of finishing work you undertake
- Who will be operating the machine
- Future production requirements
My advice as a Rollover technician
Having installed and worked on these machines, my biggest piece of advice is not to underestimate the importance of technique and maintenance.
A good Rollover can make the application process considerably easier, but the best results come when the machine, materials and operator are all working together.
Take the time to learn the correct technique, keep the machine clean, deal with small problems early and make sure everyone operating the equipment understands how it should be used.
That approach can help you get much more from your investment and keep your finishing workflow running consistently.
