Variable rotary cutter and make-ready method with knife-change-only capability

A method of readying a knife cylinder for making incisions in web materials that pass between the knife cylinder and an anvil cylinder, the method comprising the steps of:

• providing the knife cylinder with a plurality of knife holder devices circumferentially positioned about the circumference of the knife cylinder, at least some of the knife holder devices defining knife holders that extend the axial length of the knife cylinder and are configured to permit multiple knife blades of different lengths to be mounted therein end-to-end across the axial length of the knife cylinder in its entirety;
• mounting at least one knife blade in at least a first of the knife holders while not mounting any knife blades in at least a second of the knife holders;
• rotating the knife cylinder to form incisions spaced apart a first spacing distance in a web material passing between the knife and anvil cylinders;
• and then
• reconfiguring the knife cylinder without repositioning any of the knife holders on the knife cylinder by performing at least one step chosen from the group consisting of repositioning the at least one knife blade on the first knife holder, removing the at least one knife blade from the first knife holder, and mounting at least one knife blade in the second knife holder;
• and
• rotating the knife cylinder to form incisions spaced apart a second spacing distance in a web material passing between the knife and anvil cylinders, wherein the first and second spacing distances are different.