Apparatus and method for minimizing waste and improving quality and production in web processing operations by automatic cuff defect correction

A defect correction system for correcting defects in a fold of a running web having elastic strands thereon, the system comprising:

• an arrangement of a drive roller and idle roller configured to translate the running web in a machine direction at a feed rate;
• a guide roller positioned to receive the running web as it translates in the machine direction;
• a correction roller configured to selectively engage the running web and elastic strands;
• a folding board positioned downstream from the guide roller and configured to create a running fold in the running web that has a cross-direction fold width along the machine direction;
• a defect detection system configured to monitor the running fold for a predetermined change in cross-direction fold width from an initial fold width;
• and
• a controller programmed to:
• receive an input from the defect detection system comprising the cross-direction fold width of the running fold;
• and
• identify the predetermined change in cross-direction fold width from the initial fold width;
• and
• wherein, when the predetermined change in cross-direction fold width is identified, the correction roller operates to engage with the running web and disengage from the running web.