Machine for processing a web of material, and method for changing rolls on a machine

Abstract

An interfolder has a main frame structure, and a sub-frame structure moveable relative to the main frame structure between engaged and disengaged positions. A first cutoff roll frame is securable to the main frame structure and comprises a first pre-fold roll. A second cutoff roll frame is securable to the sub-frame structure and comprises a second pre-fold roll. A first folding roll frame releasably connects with the main frame structure and comprises a first folding roll. A second folding roll frame releasably connects with the sub-frame structure and comprises a second folding roll. When the sub-frame structure is in the engaged position with the main frame structure, the first and second folding roll frames are in position for normal operation. When the sub-frame structure is in the disengaged position with the main frame structure, the first and second folding roll frames are in position for removal from the machine.

Description

[0001]MACHINE FOR INTERFOLDED PRODUCTS RELATED APPLICATION DATA This application claims priority benefit of US provisional application ser. no. 63 / 553,257. Filed February 14, 2024, the disclosure of which is incorporated by reference herein. BACKGROUND This disclosure is directed to methods and apparatus for producing interfolded products. In one aspect, methods and apparatus for varying the folded width of interfolded products are disclosed. In another aspect, methods and apparatus for producing a starter fold on a stack of interfolded products are disclosed. It is well known in the art that the market desires rotary interfolder machines with improved flexibility in the range of folded widths that can be produced by the machine. For instance, US 7517309 discloses an interfolding machine whose framework comprises a removable portion comprising cutting rollers, cutting tools, and folding rollers which can be changed with another removable portion provided with rollers of a diameter corresponding to the desired length of the interfolded sheets of the stack. US 7998050 discloses an interfolding machine whose framework comprises a removable portion comprising at least one cutting roller and / or at least one transfer roller. US 10308469 discloses apparatus and methods for forming sheets having different lengths, in some embodiments of which the diameter of the roll need not change, and in some embodiments of which the spacing between adjacent rolls need not be changed when transitioning from one sheet length to another sheet length. US 7584698 and 10730274, and EP 3272512, disclose methods and apparatus for changing rolls in a machine for embossing or embossing-laminating. PCT patent application WO2023021386A1 discloses a machine for interfolding a web or sheet of paper. The machine is equipped with an interfolding unit that is able to cut the web in sheets of predetermined length before folding or interfolding them. It is also well known to provide a machine with a starter fold for an end user (consumer). When a starter fold is provided, a consumer can reach into a new package of folded or interfolded products (typically through an opening at the center of the package) and grasp the starter fold to begin using the stack of webs. US 4824426 discloses a method and apparatus for a starter fold (“starter tab”) in a machine for zig- zag folding a pair of continuous webs. US 6045002 discloses a method and apparatus for producing a starter fold (“starter panel”) in a stack of folded sheets including right and left Z folded sheets and right and left V folded sheets, in which the top sheet is a V folded sheet which is folded to provide a starter panel. As will become evident from the discussion that follows, the methods and apparatus described herein provide for improved flexibility in varying the folded width of interfolded products on a rotary interfolder machine, and for producing a starter fold on a rotary interfolder machine. DESCRIPTION OF THE DRAWINGS Figure 1 shows a front view of a typical interfolder machine and its web path routing. Figure 2 shows thumbnails of sequential processing of the web with the rollers of the right side of the interfolder machine of Figure 1. Figure 3 is a perspective view of an exemplary interfolder machine. Figure 4 is a front view of the interfolder machine of Figure 3. Figure 5 is an operator side perspective view of the framework of the interfolder machine of Figure 3. Figure 6 is a drive side perspective view of the framework of the interfolder machine of Figure 3. Figure 7A is an operator side elevation view of the framework of the interfolder machine of Figure 3. Figure 7B is an operator side elevation view of the interfolder machine of Figure 3 with some features not shown for clarity, with a movable sub-frame structure shown in a disengaged or “racked out” position. Figure 8 is a perspective view of the cut-off roll frames of the interfolder machine of Figure 3. Figure 9 is an operator side elevation view of the cut-off roll frames of the interfolder machine of Figure 3 (the drive side elevation view being substantially identical). Figure 10 is a side elevation view of the cut-off roll frames interfolder machine of Figure 3 (the opposite side elevation view being substantially identical). Figure 11 is a perspective view of the folding roll frames of the interfolder machine of Figure 3. Figure 12 is a top view of the folding roll frames of the interfolder machine of Figure 3. Figure 13 is a front schematic view of an alternate embodiment of an interfolder machine. Figure 14 is a front schematic view of the cut-off roll frames and folding roll frames of the interfolder machine of Figure 13. Figure 15 is a partial front schematic view of an alternate embodiment of an interfolder machine. Figure 16 is a partial front view of the interfolder machine of Figure 3 equipped with a starting fold apparatus. Figure 17 is a perspective view of starting fold finger assembly of the interfolder machine of Figure 16. Figure 18 is a side, cross-sectional view of the starting fold finger assembly of Figure 17. Figure 19 is a top view of the starting fold finger assembly of Figure 17. Figure 20 is a schematic view showing a first sequence of webs being folded in the interfolder machine of Figure 16. Figure 21 is a schematic view showing a next in sequence of webs being folded in the interfolder machine of Figure 16. Figure 22 is a schematic view showing the first and next in sequence of webs being folded in the interfolder machine of Figure 16. DETAILED DESCRIPTION Referring to Figures 1 and 2, the interfolder machine 20 includes a plurality of guide rolls 22, idler rolls 24, and driven rolls 26 for feeding one or more webs 28 of material to cutting rolls, for instance, a knife roll 30 and an anvil roll 32, where the web of material is cut into sheets 34. After being cut, the sheets move on to corresponding prefold or lap rolls 36 and folding rolls 38. The folding rolls 38 are opposed to each other and form a nip 40. The folding rolls 38 receive the cut sheets 34 of web material from the cutting rolls 30,32 and prefold rolls 36, and form the sheets into a stack 42 downstream of the nip 40. One or more packing fingers 44 may be associated with each of the folding rolls 38. The packing finger 44 is movable between a retracted position and an extended position relative to its respective folding roll 38. The packing finger 44 associated with one folding roll 38 moves between extended and retracted positions alternating with the movement between extended and retracted positions of the packing finger associated with the other folding roll. The packing finger 44 pushes the sheet 34 from the folding roll 38 to a position where the fold can be pressed with leading and trailing edges of the opposing sheets being folded therebetween. The process continues alternately with the other folding roll to form the stack of material 42. In the sequence of folding shown in Figure 2, a modified V fold is created as the sheet 34 is processed between the anvil roll 32, the prefold roll 36, and the folding roll 38. Other folding options may be employed including C-folding, V-folding, and Z- folding. Figures 3-7 show an embodiment of an exemplary interfolder machine 20. The machine 20 includes a main frame 50 and one or more subframes 52 that are movable relative to the main frame in the direction of process flow between engaged and disengaged positions of the subframe relative to the main frame. For instance, the subframe 52 may be mounted on rails or slides 54. The movement between the engaged and disengaged positions of the subframe 52 may be effectuated with actuators known in the art, for instance, a manual operator such as a hand-wheel, or a hydraulic, pneumatic, or electro-mechanical operator. Figures 3-7 show the subframe 52 connected with the main frame 50 in the engaged position. In the disengaged position, the subframe 52 may be released and moved away from the main frame 50 with sufficient space to allow for cleaning, maintenance and / or changeovers. When in the normal operating or engaged position, the subframe 52 is locked into and otherwise physically connected with the main frame 50. Making reference to Figures 3-12, the main frame 50 and subframe 52 of the interfolder machine 20 may each accommodate a cut-off roll frame 56 and folding roll frame 58 about a centerline 60 of the interfolder machine. In such an arrangement, the portions of the main frame 50 and subframe 52 that accommodate the cut-off roll frames 56 and the folding roll frames 58 may be mirror images about the centerline 60 of the interfolder machine 20. The portions of the main frame 50 and subframe 52 that accommodate the cut-off roll frames 56 and the folding roll frames 58 may each include respective locator surfaces 62,64 that allow the cut-off roll frame and the folding roll frames to be mounted on and supported in the respective main frame and subframe. The cut-off roll frame 56 and the folding roll frame 58 may each have respective locator surfaces 66,68 that cooperate with the respective locator surfaces 62,64 of the respective main frame 50 or subframe 52 for mounting and supporting the cut-off roll frame and the folding roll frame in the respective frame and subframe. The cut-off roll frame 56 and the folding roll frame 58 may each have additional locator surfaces 70,72 that cooperate with each other to allow the cut-off roll frame 56 to be mounted on and supported by the folding roll frame 58 when the cut-off frame and folding roll frame are mounted on and supported by the respective main frame 50 or subframe 52. The additional locator surfaces 70,72 may comprise faces of the cut-off roll frames and folding roll frames. The cut off roll frame 56 has the knife roll 30, the anvil roll 32, and the prefold roll 36 arranged in the cut off roll frame in a substantially standard format that is compatible for substantially each processing job / recipe that is expected to be processed in the interfolder machine 20. The cut-off roll frame 56 is intended to stay within the interfolder machine 20 for all product formats, and thus facilitates changeover between product formats as the cut-off roll frame 56 will not be removed from the machine but moved to a retracted position in the respective main frame and subframe as needed to allow the folding roll frames to be removed. As will be explained below, during changeover, the cut-off roll frame 56 will be moved within the respective main frame 50 and subframe 52 along the locator surfaces 62,66 as necessary to allow the folding roll frames 58 to be removed for different product formats, and the cut-off roll frame 56 may be positioned in slightly different locations within the respective main frame 50 and subframe 52 along the locator surfaces 62,66 and the additional locator surfaces 70,72 depending upon the folding roll frame 58 used for normal processing operations. The folding roll frame 58 includes the folding roll 38. The overall structure, and the arrangement of the locator surfaces 68 and the additional locator surfaces 72, of the folding roll frame 58 are intended to be somewhat uniform in shape from one folding roll frame to another folding frame, but scaled in size according to the diameter of the folding roll. However, the folding roll 38 contained in the folding roll frame 58 will vary from folding roll frame to folding roll frame with a different folding roll arrangement in each frame as may needed for differing product formats. For instance, depending upon the product format and the specific processing job / recipe, the size and surface features of the folding roll 38 arranged in the folding roll frame 58 may vary from one folding roll frame to another folding roll frame. As the overall structure and locator surfaces 68 and additional locator surfaces 72 of the folding roll frame are generally the same from one folding roll frame to another folding frame, each folding roll frame 58 will be mounted in and supported by the respective main frame 50 and subframe 52 along the locator surfaces 64,68 in generally the same location, and the cut-off roll frame 56 will also be mounted in and supported by the respective main frame 50 and subframe 52 along the locator surfaces 62,66 and the additional locator surface 70,72 in generally the same location with slight variations depending upon the size of the folding roll frame for normal processing operations. Accordingly, during changeover to a new product format, for instance, a product having a change in the folded width, the main frame 50 and subframe 52 may be moved from the engaged position to the disengaged position allowing room for the folding roll frames 58 to be removed from the main frame and the subframe, and the folding roll frames may be replaced with different folding roll frames with different sized folding rolls. The locator surfaces 68 and the additional locator surfaces 72 of the folding roll frames 58 may be slightly different and have different overall sizes to accommodate the range of product formats and cut-off widths. The cutoff roll frames may be moved to the retracted positions away from the folding roll frames to allow additional clearance for removal of the folding roll frames. The additional locator surfaces 70,72 between the cut-off roll frame 56 and the folding roll frame 58 may be adapted and configured to allow the cut-off roll frame to butt up against a particular folding roll frame and set the basic gap distance between the prefold roll 36 of the cut-off roll frame and the folding roll 38 of the folding roll frame for normal processing operations. The folding roll frames 58 may also be adapted and configured to cooperate with each other about the centerline 60 of the interfolder machine 20 to set the basic gap distance or nip 40 between the folding rolls 38 for a specific product format for normal processing operations. Making reference to Figures 8-10, the cut-off roll frame 56 for the main frame 50 or subframe 52 may have a front face 80 and a rear face 82 with supports 84 extending between the faces. The front face 80 and the rear face 82 may be similar in construction and may be substantially similar in construction and functionality. Each of the faces 80,82 may include openings to accommodate drives and bearings associated the rolls 30,32,36. In addition, each of the faces 80,82 may include movable subplates 85 that support the prefold roll 36. The subplates 85 may be assembled within the cut- off roll frame 56, and fine tuning of the position of the subplate 85, and thus the prefold roll 36, within the cut-off roll frame 56 may be provided with jack screws 86. Fine tuning may be needed to adjust the gap between the prefold roll 36 and the folding roll 38 and / or to adjust squareness and / or parallelism of the prefold roll relative to the other rolls. The locator surfaces 66 of the cut-off roll frames 56 may be provided on the angled peripheral edges of each face 80,82. So, the cut-off roll frame 56 may be positionable along the locator surfaces 62 of the respective main frame 50 and subframe 52 by sliding the cut-off roll frame 56 along the locator surfaces of the angled peripheral edges 66. In particular, during changeover of the folding roll frames 58, the cut-off roll frames 56 may be moved upward and outward away from the folding roll frames along the locator surfaces 62,66. To assist in positioning the cut-off roll frames 56 along the locator surfaces 62 of the respective frame 50 and subframe 52, a turn buckle 88 may be provided on the face 80,82 of each cut-off roll frame 56. In the alternative, a pneumatic or hydraulic actuator may be provided, or a motor driven screw system may be provided. Once the folding roll frames 58 have been changed over, and the main frame 50 and the subframe 52 has been moved from the disengaged position to the engaged position, the cut-off roll frames 56 may be moved downward and inward toward the folding roll frames 58 along the locator surfaces 62,66 using the same turn buckle 88 or positioning means. Making reference to Figures 11 and 12, the folding roll frames 58 for the main frame 50 or subframe 52 may have a front face 90 and a rear face 92 with supports 94 extending between the faces. The front face 90 and rear face 92 may be similar in construction and may be substantially similar in construction and functionality. Each of the faces 90,92 may include an opening to accommodate drives and bearings associated the folding rolls 38. The locator surfaces 68 of the folding roll frames 58 may be provided on the bottom peripheral edges of each face 90,92. So, the folding roll frame 58 is essentially fixable in position along the locator surfaces 64 of the respective main frame 50 and subframe 52. During changeover of the folding roll frames 58, the folding roll frames are removed from the machine 20. The folding roll frames 58 each have their additional locator surfaces 72 on the upward facing angled peripheral edges so as to engage the additional locator surfaces 70 of the cut-off roll frames 56. As mentioned above, once the folding roll frames 58 have been changed over, the cut-off roll frames 56 may be moved downward and inward toward the folding roll frames along the locator surfaces 62,66 using the turn buckle 88 or positioning means. Placing the cut-off roll frame 56 in position with folding roll frame 58 establishes the required spacing for the nip between the prefold roll 36 and the folding roll 38. Also, placing the folding roll frames 58 in position in the normal operating position (e.g., the engaged position of the main frame 50 and subframe 52) establishes the required spacing for the nip 40 between the folding rolls 38. Fine tuning adjustments, for example based on web material type and / or thickness, may be made with the jack screws 86 on the subplate 85 of the cut-off roll frame 56. Figures 13-14 provide another example of the interfolder machine 120 with a main frame 150 and subframe 152 moveable on rails 154. The cut-off frames 156 and folding roll frames 158 having a different overall shape but with a functionality the same as described above. Figure 15A provides another example of the interfolder machine 220 with two opposing subframes 252 mounted on a frame 250. Each opposing subframe 252 contains draw rolls 260, knife rolls 262, and folding rolls 264. The interfolder machine 220 has stationary knives (not shown) that are positioned each knife roll 262 and cooperate with each knife roll to cut the web. Each opposing subframe 252 is adapted and configured to slide on ways 254 relative to the main frame 250 to allow sufficient space between the subframe for cleaning, maintenance and / or changeovers. Figures 16-22 provide additional detail of a mechanism 300 for forming a starting fold for a stack on an interfolder machine, which may be any interfolder machine, for instance, the interfolder machine 20 of Figures 3-12, the interfolder machine 120 of Figures 13-14, or the interfolder machine 220 of Figure 15. The starting fold mechanism creates a starting fold or pick point for the sheets 34 in the stack 42 the top and toward the center of each stack. When in package, the user can grab at the center of the package to remove the sheets. The starting fold mechanism 300 may be incorporated into a new machine during manufacture or retrofitted onto an existing machine . Making reference to Figures 16-22, the starting fold mechanism 300 includes a folding finger assembly 302 that moves in a reciprocating fashion, for instance, horizontal reciprocal motion, relative to the last or top sheet 304 in the stack to fold over the last or top sheet in a completed stack 306 as the completed stack is moving downward in the machine and the last or top sheet is being separated from a nascent or new stack 308 being formed above the completed stack. The folding finger assembly 302 includes a plurality of fingers 310 projecting outward from a support 312. An actuator 314 operatively connected between the support 312 and the frame 350 of the interfolder machine may be used to move or reciprocate the folding finger assembly 300 between disengaged and engaged positions. In the disengaged position, the folding finger assembly is retracted from the downward path of travel of the stacks so as to prevent interference with the packing fingers 44. In the engaged position, the folding finger assembly is extended into the downward path of travel of the stacks so as to engage the last or top sheet of the completed stack 306. The actuator 314 may be a pneumatic or hydraulic cylinder actuator, or in the alternative, a servo motor driving a belt may be used in a manner similar to that used for conventional actuation of the packing fingers 44 of the interfolder machine. Making reference to Figures 20-22, which show the sequence for forming the starting fold for the completed stack 306, as the completed stack is being completed on a stacker finger assembly 352, the fingers 320 of the following finger assembly 322 engages the top of the completed stack 306 and move the completed stack downward in the interfolder machine with the stack positioned on the stacker finger assembly 352 onto a discharge conveyor (not shown) and away from the new stack 308 being formed above the completed stack. The following finger assembly 322 is adapted and configured to hold pressure on the top completed stack 306 during movement of the stack downward onto the discharge conveyor. Distal ends of the fingers 320 of the following finger assembly 322 may be positioned at the center of the completed stack 306 to create the starting fold at the center of the stack, or alternatively, create a starting fold that places the end of the sheet at the center of the stack if the following finger assembly is offset. With the following finger assembly 322 in engagement with the completed stack 306 and with the stack moving downward in the machine and the last or top sheet 304 extending between the completed stack and the newly forming stack 308, the folding finger assembly 302 moves from the disengaged position to the engaged position. The distal ends of the fingers 310 of the folding finger assembly 302 engage the last or top sheet 304 in a manner to fold the last or top sheet of the completed stack 306 over the top of the fingers 320 of the following finger assembly 322 and to leave a folded edge at the top of the completed stack 306 approximately in the center of the completed stack. Once the last or top sheet 304 in the completed stack 306 is folded over with the folding finger assembly 302, the folding finger assembly 302 moves to the disengaged position to await completion of the next stack at which point the process repeats. Further embodiments can be envisioned by one of ordinary skill in the art after reading this disclosure. In other embodiments, combinations or sub-combinations of the above-disclosed invention can be advantageously made. The example arrangements of components are shown for purposes of illustration and it should be understood that combinations, additions, re-arrangements, and the like are contemplated in alternative embodiments of the present invention. Thus, various modifications and changes may be made thereunto without departing from the broader spirit and scope of the invention as set forth in the claims and that the invention is intended to cover all modifications and equivalents within the scope of the following claims.

Claims

What is claimed is:

1. A machine for processing a web of material, the machine comprising: a main frame structure; a sub-frame structure adapted and configured to be moveable relative to the main frame structure between an engaged position and a disengaged position, wherein when the sub-frame structure is in the engaged position, the sub-frame structure is operatively securable to the main frame structure for performance of normal operations processing the web of material in the machine, and wherein when the sub-frame structure is in the disengaged position, the sub-frame structure is spaced from the main frame structure for suspension of normal operations processing the web of material in the machine; a first cutoff roll frame operatively securable to the main frame structure, the first cutoff roll frame comprising a first pre-fold roll, the first cutoff roll frame being movable relative to the main frame structure to a first cutoff roll frame operating position; a second cutoff roll frame operatively securable to the sub-frame structure, the second cutoff roll frame comprising a second pre-fold roll, the second cutoff roll frame being movable relative to the sub-frame structure to a second cutoff roll frame operating position; a first folding roll frame adapted and configured to releasably connect with the main frame structure, the first folding roll frame comprising a first folding roll; a second folding roll frame adapted and configured to releasably connect with the sub-frame structure, the second folding roll frame comprising a second folding roll; wherein when the sub-frame structure is in the engaged position with the main frame structure, the first folding roll frame is operatively secured with the main frame structure, and the first cutoff roll frame is in the first cutoff roll frame operating position,the first pre-fold roll is spaced from the first folding roll at a first frame prefold distance for the performance of normal operation processing the web of material in the machine; wherein when the sub-frame structure is in the engaged position with the main frame structure, the second folding roll frame is operatively secured with the sub-frame structure, and the second cutoff roll frame is in the second cutoff roll frame operating position, the second pre-fold roll is spaced from the second folding roll at a second frame pre-fold distance for the performance of normal operation processing the web of material in the machine; and wherein when the sub-frame structure is in the engaged position with the main frame structure, the first folding roll frame is releasably connected with the main frame structure, and the second folding roll frame is releasably connected with the sub-frame structure, the first folding roll is spaced from the second folding roll at a nip distance for the performance of normal operation processing the web of material in the machine.

2. The machine of claim 1 wherein the first cutoff roll frame further comprises a first knife roll and a first anvil roll, and the second cutoff roll frame further comprises a second knife roll and a second anvil roll.

3. The machine of claim 1 wherein the sub-frame structure is moveable relative to the main frame structure in a horizontal direction perpendicular to the axis of the first folding roll.

4. The machine of claim 1 wherein:when the sub-frame structure is in the engaged position with the main frame structure, the first cutoff roll frame is in the first cutoff roll frame operating position, the first folding roll frame is releasably connected with the main frame structure, and the first pre-fold roll is spaced from the first folding roll at the first frame pre-fold distance for the performance of normal operation processing the web of material in the machine, a face of the first cutoff roll frame is in contact with a face of the first folding roll frame; and when the sub-frame structure is in the engaged position with the main frame structure, the second cutoff roll frame is in the second cutoff roll frame operating position, the second folding roll frame is releasably connected with the sub-frame structure, and the second pre-fold roll is spaced from the second folding roll at the second frame pre-fold distance for the performance of normal operation processing the web of material in the machine, a face of the second cutoff roll frame is in contact with a face of the second folding roll frame.

5. The machine of claim 1 wherein when the sub-frame structure is in the engaged position with the main frame structure, the first folding roll frame is releasably connected with the main frame structure, the second folding roll frame is releasably connected with the sub-frame structure, and the first folding roll is spaced from the second folding roll at the nip distance for the performance of normal operation processing the web of material in the machine, a face of the first folding roll frame is in contact with a face of the second folding roll frame.

6. The machine of claim 1 wherein:the first cutoff roll frame is moveable relative to the main frame structure to a retracted position, the retracted position being spaced from the first cutoff frame operating position and sufficiently spaced from the first folding roll frame when the first folding roll frame is releasably connected to the main frame structure to allow the first folding roll frame to be removed from the main frame structure; and the second cutoff roll frame is moveable relative to the sub-frame structure to a retracted position, the retracted position being spaced from the second cutoff frame operating position and sufficiently spaced from the second folding roll frame when the second folding roll frame is releasably connected to the sub-frame structure to allow the second folding roll frame to be removed from the sub-frame structure.

7. The machine of claim 1 further comprising: a further first folding roll frame adapted and configured to releasably connect with the main frame structure, the further first folding roll frame comprising a further first folding roll, the further first folding roll frame being different from the first folding roll frame; a further second folding roll frame adapted and configured to releasably connect with the sub-frame structure, the further second folding roll frame comprising a further second folding roll, the further second folding roll frame being different from the second folding roll frame; wherein the first cutoff roll frame is movable relative to the main frame structure to a first cutoff roll frame further operating position, the first cutoff roll frame further operating position is different from the first cutoff roll frame operating position;wherein the second cutoff roll frame is movable relative to the sub-frame structure to a second cutoff roll frame further operating position, the second cutoff roll frame further operating position is different from the second cutoff roll frame operating position; wherein when the sub-frame structure is in the engaged position with the main frame structure, the further first folding roll frame is releasably connected with the main frame structure, and the first cutoff roll frame is in the first cutoff roll frame further operating position, the first pre-fold roll is spaced from the further first folding roll at a further first frame pre-fold distance for normal operation processing the web of material in the machine; wherein when the sub-frame structure is in the engaged position with the main frame structure, the further second folding roll frame is releasably connected with the sub- frame structure and the further second cutoff roll frame is in the second cutoff roll frame further operating position, the second pre-fold roll is spaced from the further second folding roll at a further second frame pre-fold distance for normal operation processing the web of material in the machine; and wherein when the sub-frame structure is in the engaged position with the main frame structure, the further first folding roll frame is releasably connected with the main frame structure, and the further second folding roll frame is releasably connected with the sub-frame structure, the further first folding roll is spaced from the further second folding roll at a further nip distance for the performance of normal operation processing the web of material in the machine.

8. The machine of claim 7 wherein:when the sub-frame structure is in the engaged position with the main frame structure, the first cutoff roll frame is in the first cutoff roll frame further operating position, the further first folding roll frame is releasably connected with the main frame structure, and the first pre-fold roll is spaced from the further first folding roll at the further first frame pre-fold distance for the performance of normal operation processing the web of material in the machine, a face of the first cutoff roll frame is in contact with a face of the further first folding roll frame; and when the sub-frame structure is in the engaged position with the main frame structure, the second cutoff roll frame is in the second cutoff roll frame further operating position, the further second folding roll frame is releasably connected with the sub-frame structure, and the second pre-fold roll is spaced from the further second folding roll at the further second frame pre-fold distance for the performance of normal operation processing the web of material in the machine, a face of the second cutoff roll frame is in contact with a face of the second folding roll frame.

9. The machine of claim 7 wherein when the sub-frame structure is in the engaged position with the main frame structure, the further first folding roll frame is releasably connected with the main frame structure, the further second folding roll frame is releasably connected with the sub-frame structure, and the further first folding roll is spaced from the further second folding roll at the further nip distance for the performance of normal operation processing the web of material in the machine, a face of the further first folding roll frame is in contact with a face of the further second folding roll frame.

10. The machine of claim 7 wherein:the first cutoff roll frame is moveable relative to the main frame structure to a retracted position, the retracted position being spaced from the first cutoff frame further operating position and sufficiently spaced from the further first folding roll frame when the further first folding roll frame is releasably connected to the main frame structure to allow the further first folding roll frame to be removed from the main frame structure; and the second cutoff roll frame is moveable relative to the sub-frame structure to a retracted position, the retracted position being spaced from the second cutoff frame further operating position and sufficiently spaced from the further second folding roll frame when the further second folding roll frame is releasably connected to the sub-frame structure to allow the further second folding roll frame to be removed from the sub-frame structure.

11. A method for changing rolls on a machine, the method comprising: providing a first cutoff roll frame comprising a first pre-fold roll; providing a second cutoff roll frame comprising a second pre-fold roll; providing a first folding roll frame comprising a first folding roll; providing a second folding roll frame comprising a second folding roll; releasably connecting the first folding roll frame to a main frame structure; releasably connecting the second folding roll frame to a sub-frame structure; moving the sub-frame structure relative to the main frame structure from a disengaged position wherein the sub-frame structure is spaced from the main frame structure to an engaged position wherein the sub-frame structure is operatively securable to the main frame; operatively securing the sub-frame structure to the main frame structure;operatively securing the first cutoff roll frame to the main frame structure at a first cutoff roll operating position; operatively securing the second cutoff roll frame to the sub-frame structure at a second cutoff roll operating position; wherein with the sub-frame structure operative secured with the main frame structure: the step of operatively securing the first cutoff roll frame to the main frame structure at the first cutoff roll frame operating position includes positioning the first pre-fold roll relative to the first folding roll at a first frame pre-fold distance for the performance of normal operation processing the web of material in the machine; the step of operatively securing the second cutoff roll frame to the main frame structure at the second cutoff roll frame operating position includes positioning the second pre-fold roll relative to the second folding roll at a second frame pre-fold distance for the performance of normal operation processing the web of material in the machine; and the steps of releasably connecting the first folding roll frame with the main frame structure, and releasably connecting the second folding roll frame with the sub-frame structure, include positioning the first folding roll relative to the second folding roll at a nip distance for the performance of normal operation processing the web of material in the machine.

12. The method of claim 11 wherein: the step of providing the first cutoff roll frame further comprises providing the first cutoff roll frame with a first knife roll and a first anvil roll; andthe step of providing the second cutoff roll frame further comprises providing the second cut-off roll frame with a second knife roll and a second anvil roll.

13. The method of claim 11 wherein: the step of moving the sub-frame structure relative to the main frame structure includes moving the sub-frame structure in a horizontal direction perpendicular to the axis of the first folding roll.

14. The method of claim 11 wherein with the sub-frame structure operatively secured with the main frame structure, the first folding roll frame releasably connected with the main frame structure, and the second folding roll frame releasably connected with the sub-frame structure: the step of operatively securing the first cutoff roll frame to the main frame structure in the first cutoff roll frame operating position includes positioning a face of the first cutoff roll frame in contact with a face of the first folding roll frame; and the step of operatively securing second cutoff roll frame to the sub-frame structure in the second cutoff roll frame operating position includes positioning a face of the second cutoff roll frame in contact with a face of the second folding roll frame.

15. The method of claim 11 wherein with the sub-frame structure operatively secured with the main frame structure, the first folding roll frame releasably connected with the main frame structure, and the second folding roll frame releasably connected with the sub-frame structure, the step of operatively securing the sub-frame structure to the mainframe structure includes positioning a face of the first folding roll frame in contact with a face of the second folding roll frame.

16. The method of claim 11 further comprising: moving the first cutoff roll frame relative to the main frame structure to a retracted position, the retracted position being spaced from the first cutoff frame operating position and spaced from the first folding roll frame when the first folding roll frame is releasably connected to the main frame structure; and moving the second cutoff roll frame relative to the sub-frame structure to a retracted position, the retracted position being spaced from the second cutoff frame operating position and spaced from the second folding roll frame when the second folding roll frame is releasably connected to the sub-frame structure; and with the sub-frame structure in the disengaged position relative to the main frame structure: removing the first folding roll from the main frame structure; and removing the second folding roll from the sub-frame structure.

17. The method of claim 16 further comprising: providing a further first folding roll frame, the further first folding roll frame comprising a further first folding roll, the further first folding roll frame being different from the first folding roll frame; providing a further second folding roll frame, the further second folding roll frame comprising a further second folding roll, the further second folding roll frame being different from the second folding frame;releasably connecting the further first folding roll frame to the main frame structure; releasably connecting the further second folding roll frame to the sub-frame structure; moving the sub-frame structure relative to the main frame structure from the disengaged position to the engaged position; operatively securing the sub-frame structure to the main frame structure; operatively securing the first cutoff roll frame to the main frame structure at a first cutoff roll frame further operating position, the first cutoff roll frame further operating position being different from the first cutoff roll frame operating position; operatively securing the second cutoff roll frame to the sub-frame structure at a second cutoff roll further operating position, the second cutoff roll frame further operating position being different from the second cutoff roll frame operating position; wherein with the sub-frame structure operatively secured with the main frame structure: the step of operatively securing the first cutoff roll frame to the main frame structure at the first cutoff roll frame further operating position includes positioning the first pre-fold roll relative to the further first folding roll at a further first frame pre-fold distance for the performance of normal operation processing the web of material in the machine; the step of operatively securing the further second cutoff roll frame to the sub-frame structure at the second cutoff roll frame further operating position includes positioning the second pre-fold roll relative to the further second folding roll at a further second frame pre-fold distance for the performance of normal operation processing the web of material in the machine; andthe steps of releasably connecting the further first folding roll frame with the main frame structure, and releasably connecting the further second folding roll frame with the sub-frame structure includes positioning the further first folding roll relative to the further second folding roll at a further nip distance for the performance of normal operation processing the web of material in the machine.

18. The method of claim 17 wherein with the sub-frame structure operatively secured with the main frame structure, the further first folding frame releasably connected with the main frame structure and the further second folding frame releasably connected with the sub-frame structure: the step of operatively securing the first cutoff roll frame to the main frame structure in the first cutoff roll frame further operating position includes positioning a face of the first cutoff roll frame in contact with a face of the further first folding roll frame; and the step of operatively securing second cutoff roll frame to the sub-frame structure in the second cutoff roll frame operating position includes positioning a face of the second cutoff roll frame in contact with a face of the further second folding roll frame.

19. The method of claim 17 wherein with the sub-frame structure operatively secured with the main frame structure, the further first folding roll frame releasably connected with the main frame structure, and the further second folding roll frame releasably connected with the sub-frame structure, the step of operatively securing the sub- frame structure to the main frame structure includes positioning a face of the further first folding roll frame in contact with a face of the further second folding roll frame.

20. The method of claim 17 wherein: the step of operatively securing the first cutoff roll frame to the main frame structure at a first cutoff roll frame further operating position includes moving the first cutoff roll frame from the retracted position to the first cutoff frame further operating position to contact the further first folding roll frame with the further first folding roll frame releasably connected to the main frame structure; and the step of operatively securing the second cutoff roll frame to the main frame structure at a second cutoff roll frame further operating position includes moving the second cutoff roll frame from the retracted position to the second cutoff frame further operating position to contact the further second folding roll frame with the further second folding roll frame releasably connected to the sub-frame structure.

21. A method of forming a stack of interfolded sheets, wherein a top of the stack is formed from a last sheet placed in the stack, a bottom of the stack is formed from a first sheet in placed in the stack, each sheet in the stack comprises at least two fold panels, the at least two fold panels of each sheet comprises at least a first fold panel and a last fold panel, the last fold panel of each sheet is placed on the stack after the first fold panel of each sheet is placed on the stack, the method comprising the steps of: a) disposing the first sheet of the stack on at least one stacker finger to form the bottom of the stack; b) successively placing additional sheets on top of each other to form the stack with a plurality of interfolded sheets; c) engaging the last sheet in the stack with at least one following finger; andd) folding the last fold panel of the last sheet in the stack over the following finger to form a starter fold panel for the stack.

22. The method of claim 21 in which each sheet in the stack of interfolded sheets comprises a modified V-fold comprising three fold panels.

23. The method of claim 21 in which each sheet in the stack of interfolded sheets comprises a V-fold comprising two fold panels.

24. The method of claim 21 wherein the step of folding the last fold panel of the last sheet in the stack over the following finger to form a starter fold panel for the stack includes moving at least one folding finger in a manner to engage the last fold panel of the last sheet in the stack and fold the last fold panel of the last sheet in the stack over the following finger.

25. The method of claim 24 wherein the step of moving the at least one folding finger in a manner to engage the last fold panel of the last sheet in the stack and fold the last fold panel of the last sheet in the stack over the following finger includes moving the at least folding finger horizontally toward the last sheet in the stack.

26. The method of claim 21 wherein the step of engaging the last sheet in the stack with the at least one following finger includes engaging a center of the stack with the at least one following finger.

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